Harley Davidson 2009 Dyna Models. Service manual - page 27

2009 DYNA WIRING DIAGRAMS

Refer to the table below for wiring diagram information.

Wiring Diagram List

LOCATION

DIAGRAM

Figure B-2

Main Harness (1 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-3

Main Harness (2 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-4

Main Harness (3 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-5

Charging Circuit: 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-6

Starting Circuit: 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-7

Ignition Circuit: 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-8

Lights (1 of 2): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-9

Lights (2 of 2): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-10

Horn and Instruments Circuit: 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-11

Security (1 of 2): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-12

Security (2 of 2): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-13

Main Harness (1 of 3): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

Figure B-14

Main Harness (2 of 3): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

Figure B-15

Main Harness (3 of 3): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

Figure B-16

Charging Circuit: 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

Figure B-17

Starting Circuit: 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

Figure B-18

Ignition Circuit: 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

Figure B-19

Lights (1 of 2): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

Figure B-20

Lights (2 of 2): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

Figure B-21

Horn and Instruments Circuit: 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

Figure B-22

Security Circuit (1 of 2): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

Figure B-23

Security Circuit (2 of 2): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)

HOME

B-4  2009 Dyna Service:  Appendix B Wiring

IGN - 15A

INSTR - 15A

Lights - 15A

ACCY - 15A

[31RA]

[91A]

(Gray)

Data

Link

Connector

Ignition

Switch

To

Headlamp

See Sheet 3

[7A]

[33A]

[33B]

[64B]

To

Front

Turn

Signals

See Sheet 3

[38A]

To Rear

Lighting

Harness

See

Sheet 3

Fuel Pump

& Sender

Assembly

See Sheet 2

Intake Air

Temp Sensor

Throttle

Position

Sensor

Engine

Temp

Sensor

Front

Injector

Rear

Injector

Idle Air

Control

System
Relay

Battery - 15A

Fuel Pump - 15A

ECM - 15A

T

ur

n

Signal

&

Secur

ity

Module

TSM/TSSM/HFSM

To

Left Hand

Controls

(Gray)

See Sheet 3

To

Right Hand

Controls

(Black)

See Sheet 3

Security

Siren

To Instrument

Assembly

See Sheet 3

Start
Relay

(Gray)

Fuel

Gauge

See

Sheet 2

(Optional)

2

1

4

3

6

5

8

7

10

9

12

11

2

1

4

3

6

5

8

7

10

9

12

11

B

A

C

B

A

C

[62B]

[90A]

Vehicle

Speed

Sensor

R/

Starter
Solenoid

[20A]

[117B]

[141B]

[90B]

[88A]

[88B]

Power

Signal

Ground

[30B]

[30A]

[84B]

[84A]

[85B]

[85A]

[128B]

Ignition

Coil

P & A

Battery

[160B]

P&A IGN - 15A

[5]

40 Amp

MAXIFUSE

A

B

See Figure B-5

For Further

Connections
To Charging

System

[GND1]

Rear Ground

Stud Under

Electrical Center

Rear
Stop Lamp
Switch

[121]

1 2 3 4 5 6

1 2 3 4 5 6 7 8

A B

A B

1

4

3

2

5 6

C

B

A

C

B

A

Manifold

Absolute

Pressure

Sensor

2

3

4

R

BK

Crank Position Sensor

3

2

1

4

2

1

2

1

B

A

B

A

B

A

B

A

Battery

System Relay

Active Exhaust Feedback (HDI)

Serial Data

Engine Temperature

Intake Air Temperature

Oxygen Sensor (A)

Jiffy Stand Sensor (HDI)

Ground

Coil Rear

Crank POS Sensor (-)

Switched Power

5V Sensor Power

Idle Air Control (A) Hi

Idle Air Control (B) Low

Injector Rear

Active Exhaust (HDI)

Injector Front

Active Intake Solenoid (HDI)

Oxygen Sensor (B)

Throttle POS Sensor Input

Map Sensor Input

5V Sensor Ground

Ion Sense

Ground

Coil Front

Crank POS Sensor (+)

Battery

Vehicle Speed Sensor Input

Idle Air Control (A) Low

Idle Air Control (B) Hi

Ignition

Serial Data

Neutral Switch

Left Turn Feed

Right Turn Feed

Right Turn Switch Input

Left Turn Switch Input

Start Relay Control

Clutch Switch

Alarm Signal

Ground

1 2

4

A

B

C

D

A

B

C

D

Power

Ion Sense

Coil Rear

Coil Front

1 2

1 2

B A

B A

1

A B C D

A B C D

ECM

1

4
5
6
7
8
9

10
11
12
13
14

17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

33

35
36

1

4
5
6
7
8
9

10
11
12
13
14

17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

33

35
36

A
B
C

A B C D

12

1 2 3 4 5 6 7 8 9 10

[131]

Neutral

Switch

[120]

[62]

[64]

Oil Pressure

Sending Unit

[31LA]

1

2

3

3

2

1

A

B

C

[122]

Horn

Customer

Accessory

Connector

4

3

2

1

CUST ACCY - 15A

Spare - 15A

ENG CTL - 15A

See

Sheet

2

2

1

3

2

1

3

See Sheet 2

2

1

2

1

[4A]

7 8

See Sheet 2

See Sheet 2

See Sheet 2

See Sheet 2

See
Sheet 2

A

B

[GND2]

B

A

1

See Sheet 4 For Hands
Free Security Antenna

ACC − C

BATT − B

IGN − A

GN/BN

BK/PK

GN/GY

BE/GY

BE/GN

GYBE

LGN/V

GY/BE
BK/GN

BK/GN

BK/GN

LGN/V

LGN/Y

V/BE

GN/O

W/BN

BK/R

PK/Y

PK/O

GY/O

BK/O

W/GN

BE/O

GY/V

Y/BE

W/BK

BK/W

W/GN

BN/R

Y/GN

Y/BE

BE/O

GY

TN

BN

BK

BK

W/V

R/W

V

BN/GY

BN/GY

LGN/BN

LGN/BN

TN/GN

LGN/V

V/W

R/W

V/O

W/Y

R

PK/GN

BN

BK

TN

TN

BK

BK

BK

BE

BE

BN

BK

BE

GY

GN

GN

BK

BK

BK

BK

BE

GY

BK

BK

BK

BE

BK

BN

BK

GY

W/Y

Y/W

Y/W

Y/W

R/W

V/W

O/W

O/R

O/R

O/R

R/Y

O/W

O/W

O/W

O/W

R/Y

O/W

W/V

R/Y

R/Y

R/W

O

R

O

V

W

V

R

R

R

R

R

R

O

V

Y

Y

W

W

LGN/V

BN/GY

GN/GY

BK/GN

BK/GN

BK/GN

BN/GY

TN/GN

BE/GY

BE/GY

LGN/R

BK/PK

BE/GN

LGN/Y

GN/Y

GN/Y

O/W

BK/W

Y/GN

Y/GN

O/GY

Y/GN

R/BK

R/BK

R/BK

R/BK

R/BK

R/GY

R/BK

R/GY

R/GY

R/BK

BK/R

W/BK

Y/GN

O/GY

GN/O

Y/BK

Y/BK

W/BK

W/BN

BK/R

BK/R

GY/V

BK/W

LGN/Y

BK/W

BK/W

BN/R

BK/O

BK/W

PK/Y

BK/GN

BK/GN

BK/GN

BK/GN

Fuseblocks

Accessories

Lights

Ignition

Instruments

Top View

Top View

F

E

D

C

B

A

L

K

J

I

H

G

U

S

R

P

O

M

B

A

H

G

O

M

C

I

Q P

R

E

K

T S

U

Fuel Pump

Start Relay System Relay

ECM

P&A IGN

Battery

Spare

Spare

Eng CTL

Cust ACCY

[80A]

[80B]

[79A]

[79B]

[142B]

[142A]

[78B]

[78A]

[83B]

[83A]

[65B]

[89B

[89C]

[89D

[89A]

[87B]

[87A]

[24B]

[22B]

86

85

30

87A

87

1

2

3

4

5

R

P

C

Q

I

86

85

30

87A

87

1

2

3

4

5

U

S

E

T

K

F

E

S

U

D

C

G

H

A

B

M

O

P

R

I

J

O

M

A

B

G

H

et00168

Figure B-2. Main Harness (1 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-2.

Figure B-2.

Main Harness (1 of 3): 2009 All Dyna DOM. and INT. Models

(Except FXDC, FXDF)

Main Harness (1 of 3): 2009 All Dyna DOM. and INT. Models

(Except FXDC, FXDF)

S

U

IGN - 15A

INSTR - 15A

Lights - 15A

ACCY - 15A

[64B]

[62B]

Battery - 15A

Fuel Pump - 15A

ECM - 15A

A

G

I

P

M

A

G

B

H

J

R

O

B

H

P & A

Battery

P&A IGN - 15A

C

[5]

40A

MAXIFUSE

A

B

1

Cust ACCY - 15A

ENG CTL - 15A M

O

2

1

2

1

2

1

1 2

BK

BK

GY/O

LGN/R

2

1

2 3

1

2 3

1

2 1

BK

BK

Rear O

2

Sensor

Front O

2

Sensor

Active Exhaust Feedback (HDI)

Oxygen Sensor (A)

Jiffy Stand Sensor (HDI)

Ground

5V Sensor Power

Active Exhaust (HDI)

Active Intake Solenoid (HDI)

Oxygen Sensor (B)

5V Sensor Ground

Ground

Battery

Ignition

Switch

ACC − C

BATT − B

IGN − A

A
B

C

ECM

1

8
9

10

14

20

22
23

26

28

31

1

8
9

10

14

20

22
23

26

28

31

Domestic Only

HDI Only

Active Intake Solenoid

4

4

3

3

2

2

1

1

R

W

BK

5

HDI Only

Rear Ground

Stud Under

Electrical

Center

HDI Only

D

Exhaust Actuator

[GND1]

Jiffy Stand Sensor

BE

GY

BK

BK

BK

BK

BK

O/R

O/W

V/O

R/W

R/W

V/O

R

R

R

R

R

O

R

W

LGN/R

BN/GY

BE/GY

LGN/R

BK/GN

BK/GN

BK/GN

GN/BN

LGN/R

GN/BN

PK/GN

BE/GY

R/BK

R/BK

R/BK

R/BK

R/BK

R/GY

R/BK

R/GY

R/GY

Y/GN

O/GY

V/BE

GY/O

V/BE

PK/O

GY/O

BK/W

BE

GY/BK

BE

GY/BK

PK/GN

BK/W

BK/W

PK/O

BK/GN

BK/GN

P

o

w

er

Signal

Ground

Fuel Gauge

4

2

1

Full: 39.5 / 27.5

1/2 : 118.0 / 97.0

Empty: 260.0 / 240.0

A B C D

[86]

BK

BK

BK

Y/W

Y/W

O

O/GY

Fuel Pump & Sender In Tank [141A]

[138A]

[138B]

[137A]

[137B]

[33B]

[33A]

[160B]

[78B]

[78A]

[117A]

[179B]

[179A]

[133B]

[133A]

[178B]

[178A]

et01126

Figure B-3. Main Harness (2 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-3.

Figure B-3.

Main Harness (2 of 3): 2009 All Dyna DOM. and INT. Models

(Except FXDC, FXDF)

Main Harness (2 of 3): 2009 All Dyna DOM. and INT. Models

(Except FXDC, FXDF)

Front
Right

Turn

[31R]

Front

Left

Turn

Running
Lamp
(DOM
Only)

To Main
Harness

[38A]

To Main
Harness

[31L&R]

FXDL

To Main

Harness

To Main

Harness

To Main

Harness

[7A]

Right
Rear
Turn

[31R]

Right
Rear
Turn

To Main

Harness

[7A]

[31R]

Left
Rear
Turn

[31L]

Left
Rear
Turn
[31L]

Front Lighting

Rear Lighting

Position Lamp

(HDI Only)

[29]

1
2
3

Headlamp

[38]

1
2
3
4

[31L]

1

2

3
4
5

6
7

8

9

10

11
12

Trip Odometer

Reset Switch

1
2
3
4
5
6
7
8

9

10
11
12

Trip Odometer

Reset Switch

Taillamp

Taillamp

1
2

1
2
3

1

2

3

4

1

2

3

4

5

6

1
2

1
2

1
2

1

2

3

4

5

6

1

2

3

4

1

2

3

4

5

6

7

[20A]

[20A]

1

2

3

[18A]

[19A]

High

Low

Running
Light (HDI)

Running
Light (DOM)

Brake Light

FXD

FXD, FXDL

FXDB

FXDB

To Main

Harness

1
2
3
4
5
6
7
8
9

10
11
12

Trip Odometer

Reset Switch

1

1

2

2

7

7

8

8

3
4
5
6

9

10

3
4
5
6

9

10

[20A]

Speedometer

Tachometer

Serial Data

Security LP

Battery

Accessory

Ground

Trip Odometer Reset Switch

Fuel Level

Trip Odometer Reset Switch

RPM x 100

Ignition

Serial Data

Battery

Accessory

Ground

2

4

5

6

7
8

9

11

2

Ignition

1

1

4

5

6

7
8

9

11

Speedometer

Ignition

Serial Data

Security LP

Battery

Accessory

Ground

Trip Odometer Reset Switch

Fuel Level

Trip Odometer Reset Switch

1

2

4
5
6
7

8
9

11

1

2

4
5
6
7

8
9

11

Speedometer

Ignition

Serial Data

Security LP

Battery 12V

Accessory

Ground

Trip Odometer Reset Switch

Fuel Level

Trip Odometer Reset Switch

1

2

4
5
6
7
8
9

11

1

2

4
5
6
7
8
9

11

1
2

5
6
7

1
2

5
6
7

Horn Switch
Headlamp Hi/Lo Switch
Left Turn Switch

[163]

Left Hand
Controls

1 2 3 4 5 6 7 8

Clutch Switch

1

2

3

4

5

6

Right Turn Switch
Engine Stop Switch
Start Switch

Front Stop Lamp Switch

[162]

Right Hand
Controls

BN

TN

BK

BK

GY

BK

GY

GY

BK

BK

BK

BK

BK

BK

BK

BN

BN

TN

TN

BK

BK

BK

BK

BN

TN

GY

O/W

Y/W

Y/W

O/W

O/W

O/W

O/W

O/W

O

V

W

W

V

O

O

O

O

BN/GY

LGN/V

BN/GY

BN/GY

LGN/V

LGN/V

GN/Y

BN/V

GN/Y

BN/V

Y/W

Y/W

Y/W

O

W

W

V

V

O

O

O

O

BN/GY

BN/GY

BN/GY

LGN/V

LGN/V

LGN/V

GN/Y

GN/Y

BN/V

BN/V

BN/V

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BN

BE

BK

BK

BE

BE

BK

BK
BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK
BK

BK

BK

BK

BK

BK

BK

BK

BK

BN

BN

BN

TN

TN

O/W

Y/W

O

O

O

V

V

V

V

W

W

BN/GY

LGN/V

BN/V

GN/Y

GN/Y

R/Y

R/Y

O/W

BN

BN

BN

BE

BE

BE

BE

BE

BE

BE

V

V

V

W

W

Y

Y

R/Y

R/Y

O/W

O/W

O/W

BE

GY

W/V

O/W

O/W

R/Y

W

Y

Y/BK

W/BK

W/BN

BK/R

BK/R

BN/W

BN/W

O/W

BN

BK

BK

BK

BE

R/Y

V

O/W

BN

BN

BK

BK

BK
BK

BK

BE

R/Y

O/W

V/W

V/W

BK

BK

BK

BE

R/Y

V

V

R

R

O/W

BN

BK

BK

BK

BE

BN

BK

BE

BE

R/Y

O/W

BK

R/Y

V

BK

BE

V

[7B]

2

3

4

5

6

7

8

1

Converter Module

2

3

2

3

4

1

2

3

1

2

3

2

3

4

1

2

3

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

[20B]

[39B]

[39A]

[108A]

[108B]

[24A]

[22A]

[94B]

[94A]

[20B]

[21A]

[21B]

[18B]

[19B]

[20B]

[7B]

[38B]

[31RB]

[31LB]

[39B]

[39A]

[39B]

[39A]

[94B]

[94A]

[94B]

[94A]

[19A]

[19B]

[233A]

[233B]

[18A]

[18B]

et00160

Figure B-4. Main Harness (3 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

Figure B-4.

Figure B-4.

Main Harness (3 of 3): 2009 All Dyna DOM. and INT. Models

(Except FXDC, FXDF)

Main Harness (3 of 3): 2009 All Dyna DOM. and INT. Models

(Except FXDC, FXDF)

See sheet 1

for further

connections

Starter solenoid

connection

Starter

Battery

A

B

Red Band

[5B]

BK

BK

BK

BK

[47B]

[47A]

Voltage
Regulator

Front ground

stud under

electrical center

40A

MAXIFUSE

[77B]

[GND3]

Stator

[77A]

[128A]

+

–

+

–

1

3

1

3

2

2

BK

BK

BK

R

R

R

et01131

Figure B-5. Charging Circuit: 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)

4.17

EXHAUST SYSTEM

REMOVAL: ALL BUT FXDF

NOTE

If removing exhaust as an assembly and not removing mufflers,
skip muffler removal steps.

1.

Remove seat.

2.

See 

Figure 4-60

. Disconnect rear O2 sensor connector

[137]. Note wire routing for proper installation.

3.

See 

Figure 4-61

. Open front electrical caddy cover and

disconnect front O2 sensor connector [138] (1). Remove
connector housing from caddy.

4.

See 

Figure 4-62

. On models with an active exhaust

module, remove active exhaust cable (1):

a.

Remove cable (1) and retainer (2) from exhaust pipe.

b.

Remove ferrule (3) from bellcrank (4).

5.

See 

Figure 4-63

. Remove muffler support bracket nuts

(29) from bolts (30). Remove muffler support bracket (28).

6.

Loosen nuts (17) on muffler clamps (19) to exhaust pipes.
Remove mufflers (16, 27).

7.

Loosen or remove heat shields (1, 8) by opening worm
drive clamps (2).

8.

Remove flange nuts (35) from front and rear cylinder head
exhaust studs.

9.

Remove locknut (3) and bolt (41) attaching front exhaust
pipe clamp (4) to front exhaust bracket (40).

10. Remove bolt (13) and washer (14) attaching rear exhaust

pipe clamp (10) to rear exhaust bracket (23). Remove
bracket (15) if equipped.

11. Remove exhaust system as an assembly.

sm02191

Figure 4-60. Rear O2 Connector and Harness

2

1

sm03722

1.

O2 sensor connector

2.

CKP sensor connector

Figure 4-61. Front Electrical Caddy and Connectors

1

2

3

4

sm02197

1.

Active exhaust cable

2.

Cable retainer

3.

Ferrule

4.

Bellcrank

Figure 4-62. Bellcrank

HOME

2009 Dyna Service:  Fuel System  4-33

18

34

33

31

32

29

28

27

30

19

23

24

25

26

22

21

20

9

7

8

2

6

3

2

1

4

5

42

7

35

36

37

38

39

40

41

22

43

35

36

37

38

2

2

16

11

17

18

19

15

14

13

17

12

10

sm02366

31.

16.

1.

Active exhaust cable

Rear muffler

Front heat shield

2.

32.

17.

Worm drive clamp (6)

Active exhaust module

Locknut (2)

18.

3.

33.

Washer

Locknut

Washer

34.

19.

4.

Active exhaust module
fastener

Muffler clamp (2)

Exhaust pipe front clamp

5.

20.

Interconnect gasket

Cable retainer

35.

21.

6.

Flange nut (4)

Active exhaust cable clip

Rear crossover pipe heat
shield

36.

22.

Exhaust manifold flange (2)

Oxygen sensor (2, DOM only)

7.

23.

Worm drive clamp (4)

37.

Rear exhaust bracket

Retaining ring (2)

38.

24.

8.

Exhaust gasket (2)

Washer

Rear heat shield

9.

39.

25.

Rear exhaust pipe

Screw (3)

Rear exhaust bracket fastener

26.

10.

40.

Nut (2)

Rear exhaust pipe clamp

Front exhaust bracket

41.

27.

11.

Bolt

Front muffler

Muffler heat shield (2)

12.

42.

28.

Worm drive clamp (4)

Front crossover pipe heat
shield

Muffler support bracket

29.

13.

Nut

Bolt

43.

14.

Front exhaust pipe

30.

Washer

Bolt

15. Bracket (active exhaust

equipped models only)

Figure 4-63. Exhaust System: All But FXDF

HOME

4-34  2009 Dyna Service:  Fuel System

DISASSEMBLY: ALL BUT FXDF

1.

See 

Figure 4-63

. Free front exhaust pipe (43) from rear

exhaust pipe (9) by twisting and separating at crossover
pipe.

2.

Examine exhaust gaskets (38) and retaining rings (37) in
cylinder head exhaust ports. Replace if necessary.

3.

Replace the front (42) and rear (6) crossover pipe heat
shields, if necessary.

4.

Remove interconnect gasket (5) from crossover pipe bell
on rear exhaust pipe.

ASSEMBLY: ALL BUT FXDF

1.

See 

Figure 4-63

. If front (42) and rear (6) crossover pipes

heat shield were removed, install now.

2.

Insert new interconnect gasket (5) into crossover pipe bell
on rear exhaust pipe (9). Connect rear exhaust pipe to
front exhaust pipe (43) at crossover pipe.

INSTALLATION: ALL BUT FXDF

NOTES

•

See inset in 

Figure 4-63

. Replacement exhaust gaskets

(38) are tapered internally. Be sure the thin end goes over
the exhaust pipe. Also check condition of retaining ring
(37) before installation.

•

If mufflers were not removed, skip muffler installation
steps.

1.

Position ends of exhaust pipes into front and rear cylinder
head exhaust ports with holes in exhaust manifold flanges
(36) over cylinder head exhaust studs. Loosely thread on
flange nuts (35).

2.

Position front exhaust pipe clamp (4) on front exhaust
bracket (40). Install bolt (41) and locknut (3). Do not tighten
nut and bolt at this time.

3.

Position rear exhaust pipe clamp (10) and bracket (15) (if
equipped) on rear exhaust bracket (23). Install bolt (13)
and washer (14). Do not tighten bolt at this time.

NOTE

TORCA muffler clamps have eliminated the need for silicone
or graphite tape during assembly. To be sure of sealing integrity
of muffler clamps, and prevent the possibility of leakage,
Harley-Davidson recommends that the muffler clamp assem-
blies be discarded and replaced each time they are removed.

4.

Install front and rear mufflers (27, 16) on front and rear
exhaust pipes. Install muffler clamps (19) using nuts (17).
Do not tighten nuts at this time.

5.

Install muffler support bracket (28) and bracket (15) (if
equipped) using nuts (29) and bolts (30). Do not tighten
nuts at this time. Install exhaust system.

6.

Align exhaust system and tighten all nuts and bolts;
beginning at cylinder head exhaust ports and working
backwards.

7.

Tighten flange nuts (35), at front cylinder studs as follows:

a.

Install lower nut and tighten finger tight.

b.

Install upper nut and tighten to 9-18 in-lbs (1-2 Nm).

c.

Tighten lower nut to 100-120 in-lbs (11.3-13.6 Nm).

d.

Tighten upper nut to 100-120 in-lbs (11.3-13.6 Nm).

8.

Tighten flange nuts at rear cylinder studs as follows:

a.

Install upper nut and tighten finger tight.

b.

Install lower nut and tighten to 9-18 in-lbs (1-2 Nm).

c.

Tighten upper nut to 100-120 in-lbs (11.3-13.6 Nm).

d.

Tighten lower nut to 100-120 in-lbs (11.3-13.6 Nm).

9.

Open the worm drive clamps (2) and install heat shields
(1, 8).

10. Tighten nuts (29) to 15-19 ft-lbs (20.3-25.8 Nm).

11. Align mufflers. Tighten muffler clamp nuts (17) to 38-43

ft-lbs (51.6-58.4 Nm).

12. See 

Figure 4-62

. On models with an active exhaust

module, install active exhaust cable (1) to bellcrank (4):

a.

Install ferrule (3) in bellcrank.

b.

Wrap cable around bellcrank.

c.

Install cable retainer (2) on exhaust pipe.

d.

See 

Figure 4-64

. Ensure cable is properly routed and

secured.

13. See 

Figure 4-60

. Connect rear O2 sensor connector [137].

NOTE

Connector halves must be clean and dry. Do not apply dielectric
grease to sealed connectors or terminals.

14. See 

Figure 4-61

. Connect front O2 sensor connector [138].

Close front electrical caddy cover.

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)

15. Install seat.

HOME

2009 Dyna Service:  Fuel System  4-35

1

2

3

5

6

4

sm02628

1.

Rear exhaust pipe

2.

Bellcrank

3.

Battery cover

4.

Active exhaust cable

5.

Cable end

6.

Active exhaust module

Figure 4-64. Active Exhaust Bellcrank Location

REMOVAL: FXDF

NOTE

If removing exhaust as an assembly and not removing mufflers,
skip muffler removal steps.

1.

Remove seat.

2.

See 

Figure 4-65

. Disconnect rear O2 sensor connector

[137]. Note wire routing for proper installation.

3.

See 

Figure 4-66

. Open front electrical caddy cover and

disconnect front O2 sensor connector [138] (1). Remove
connector housing from caddy.

4.

See 

Figure 4-67

. On models with an active exhaust

module, remove active exhaust cable (1):

a.

Remove cable and retainer (2) from exhaust pipe.

b.

Remove ferrule (3) from bellcrank (4).

5.

See 

Figure 4-68

. Remove screw (1) attaching mufflers

together.

6.

Remove muffler support bracket bolt (4) and washer (3)
attaching mufflers (22, 23) to rear exhaust bracket (5).

7.

Loosen nuts on muffler clamps (21). Remove mufflers.

8.

Loosen or remove heat shields (16, 17, 18) by opening
worm drive clamps (15, 19).

9.

Remove flange nuts (12) from front and rear cylinder head
exhaust studs.

10. Remove head pipe assembly (14).

11. If necessary, remove flange locknuts (7) and bolt (8) to

remove muffler bracket (5).

sm02191

Figure 4-65. Rear O2 Connector and Harness

2

1

sm03722

1.

O2 sensor connector

2.

CKP sensor connector

Figure 4-66. Front Electrical Caddy and Connectors

1

2

4

3

sm03753

1.

Active exhaust cable

2.

Cable retainer

3.

Ferrule

4.

Bellcrank

Figure 4-67. Bellcrank: FXDF

HOME

4-36  2009 Dyna Service:  Fuel System

27

26

24

25

4

9

1

23

6

3

5

7

10

11

12

15

13

14

8

16

15

17

18

19

21

22

20

7

2

sm03719a

19.

10.

1.

Worm drive clamp, large (3)

Retaining ring (2)

Screw, muffler-to-muffler

2.

20.

11.

Battery tray

Cable clamp (2)

Exhaust pipe flange

12.

3.

21.

Flange nut (4)

Washer

Muffler clamp (2)

22.

13.

4.

Front (lower) muffler

Front oxygen sensor

Bolt, muffler mounting

5.

23.

14.

Muffler bracket

Rear (upper) muffler

Head pipe assembly

15.

6.

24.

Worm drive clamp, small (4)

Rear oxygen sensor

Active exhaust cable
assembly

16.

7.

Rear heat shield

Flange locknut (2)

25.

8.

Active exhaust module

17.

Bolt

Front heat shield

18.

9.

26.

Collector heat shield

Exhaust gasket (2)

Washer

27. Active exhaust module

fastener

Figure 4-68. Exhaust System: FXDF

INSTALLATION: FXDF

NOTES

•

See inset in 

Figure 4-68

. Replacement exhaust gaskets

(9) are tapered internally. Be sure the thin end goes over

the exhaust pipe. Also check condition of retaining ring
(10) before installation.

•

If mufflers were not removed, skip muffler installation
steps.

HOME

2009 Dyna Service:  Fuel System  4-37

1.

See 

Figure 4-68

. If removed, install muffler bracket.

Tighten flange locknuts (7) to 15-19 ft-lbs (20.3-25.8 Nm).
Tighten bolt (8) to 15-19 ft-lbs (20.3-25.8 Nm).

2.

Position ends of head pipe assembly (14) into front and
rear cylinder head exhaust ports with holes in exhaust
manifold flanges (11) over cylinder head exhaust studs.
Loosely install flange nuts (12).

3.

Slide muffler clamps (21) onto exhaust pipes.

NOTE

TORCA muffler clamps have eliminated the need for silicone
or graphite tape during assembly. To be sure of sealing integrity
of muffler clamps, and prevent the possibility of leakage,
Harley-Davidson recommends that the muffler clamp assem-
blies be discarded and replaced each time they are removed.

4.

Install front and rear mufflers (22, 23) on exhaust pipes.
Install muffler clamps (21). Do not tighten nuts at this time.

5.

Install muffler-to-muffler screw (1). Do not tighten at this
time.

6.

Install muffler mounting bolt (4) and washer (3). Do not
tighten at this time.

NOTE

Align exhaust system and tighten all nuts and bolts, beginning
at cylinder head exhaust ports and working backwards.

7.

Tighten flange nuts (12), at front cylinder studs as follows:

a.

Install lower nut and tighten finger tight.

b.

Install upper nut and tighten to 9-18 in-lbs (1-2 Nm).

c.

Tighten lower nut to 100-120 in-lbs (11.3-13.6 Nm).

d.

Tighten upper nut to 100-120 in-lbs (11.3-13.6 Nm).

8.

Tighten flange nuts at rear cylinder studs as follows:

a.

Install upper nut and tighten finger tight.

b.

Install lower nut and tighten to 9-18 in-lbs (1-2 Nm).

c.

Tighten upper nut to 100-120 in-lbs (11.3-13.6 Nm).

d.

Tighten lower nut to 100-120 in-lbs (11.3-13.6 Nm).

9.

Open the worm drive clamps (15, 19) and install heat
shields (16, 17, 18).

10. Tighten muffler mounting bolt (4) to 15-19 ft-lbs (20.3-25.8

Nm). Tighten muffler attaching bolt (1) securely.

11. Align mufflers. Tighten muffler clamp nuts to 38-43 ft-lbs

(51.6-58.4 Nm).

12. See 

Figure 4-67

. On models with an active exhaust

module, install active exhaust cable (1):

a.

Install ferrule (3) in bellcrank (4).

b.

Wrap cable around bellcrank.

c.

Install cable and retainer (2) on exhaust pipe.

d.

See 

Figure 4-69

. Make sure cable routing is correct

and secure with two camps (3).

NOTE

Connector halves must be clean and dry. Do not apply dielectric
grease to sealed connectors or terminals.

13. See 

Figure 4-65

. Connect rear O2 sensor connector [137].

14. See 

Figure 4-61

. Connect front O2 sensor connector [138].

Close front electrical caddy cover.

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)

15. Install seat.

1

4

2

3

sm03818

1.

Active exhaust module

2.

Active exhaust cable

3.

Clamp (2)

4.

Bellcrank

Figure 4-69. Active Exhaust Cable: FXDF

HOME

4-38  2009 Dyna Service:  Fuel System

4.18

INTAKE LEAK TEST

GENERAL

Do not allow open flame or sparks near propane. Propane
is extremely flammable, which could cause death or ser-
ious injury. (00521b)

Read and follow warnings and directions on propane
bottle. Failure to follow warnings and directions can result
in death or serious injury. (00471b)

NOTES

•

To prevent false readings, keep air cleaner cover installed
when performing test.

•

Do not direct propane into air cleaner; false readings will
result.

•

Be careful when testing vehicle with Screamin' Eagle air
cleaner assembly. This type of air cleaner has an open
backing plate. Even with air cleaner cover on, directing
nozzle too close to backing plate can give false readings.

LEAK TESTER

TOOL NAME

PART NUMBER

PROPANE ENRICHMENT KIT

HD-41417

Parts List

•

Standard 14 oz. propane cylinder.

•

PROPANE ENRICHMENT KIT (Part No. HD-41417).

Tester Assembly

1.

See 

Figure 4-70

. Make sure valve knob (6) is closed (fully

clockwise).

2.

Screw valve assembly (5) onto propane bottle (1).

Tester Adjustment

1.

See 

Figure 4-70

. Press and hold trigger button (8).

2.

Slowly open valve knob (6) until pellet in flow gauge (7)
rises to between 5 and 10 SCFH on gauge.

3.

Release trigger button.

1

8

5

9

3

2

7

4

6

sm02629

1.

Propane bottle

2.

Nozzle

3.

Copper tube

4.

Hose

5.

Valve assembly

6.

Valve knob

7.

Flow gauge

8.

Trigger button

9.

Hanger

Figure 4-70. Leak Tester

PROCEDURE

1.

Start engine.

2.

Warm up engine to operating temperature.

NOTE

Do not direct propane stream toward air cleaner. If propane
enters air cleaner, a false reading will be obtained.

3.

See 

Figure 4-71

. Aim nozzle (3) toward possible sources

of leak such as intake manifold mating surfaces.

4.

Press and release trigger button (2) to dispense propane.
Tone of engine will change when propane enters source
of leak. Repeat as necessary to detect leak.

HOME

2009 Dyna Service:  Fuel System  4-39

5.

When test is finished, close valve knob (turn knob fully
clockwise).

3

1

2

sm02630

1.

Propane bottle

2.

Trigger button

3.

Nozzle

Figure 4-71. Checking for Leaks

HOME

4-40  2009 Dyna Service:  Fuel System