Harley Davidson 2009 Dyna Models. Service manual - page 31

4.

Replace the sprocket if teeth are cracked or worn. See

5.7 TRANSMISSION SPROCKET, Cleaning and Inspec-
tion

 for more information.

5.

Inspect the needle bearings on the inside of the main drive
gear. If mainshaft race surface appears pitted or grooved,
replace these bearings.

NOTE

If the main drive gear needle bearings and/or seal need to be
replaced, continue as follows. Otherwise, proceed to

6.8 TRANSMISSION CASE, Assembly

.

Needle Bearing Replacement

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

NOTES

•

See 

Figure 6-38

. When replacing needle bearings, discard

original retaining rings (1) and install replacement retaining
rings (2).

•

To install the inner main drive gear needle bearings and
mainshaft seal, use MAIN DRIVE GEAR BEARING AND
SEAL INSTALLATION TOOL (Part No. HD-47932).

1.

See 

Figure 6-37

. Remove mainshaft seal (6). Remove

retaining rings (1), needle bearings (2) and spacer (5) from
main drive gear (3). Discard retaining rings.

2.

Remove and discard o-ring (4).

1

2

3

4

2

1

6

5

sm03036

1.

Retaining ring (2)

2.

Needle bearing (2)

3.

Main drive gear

4.

O-ring

5.

Spacer

6.

Mainshaft seal

Figure 6-37. Main Drive Gear Assembly

1

2

sm03038

1.

Original retaining ring

2.

Replacement retaining ring

Figure 6-38. Main Drive Gear Retaining Rings

3.

See 

Figure 6-39

. Install clutch side needle bearing using

an arbor press and the 0.400 in. step end of tool as shown.
Press until tool contacts gear.

sm03040

Figure 6-39. Installing Clutch Side Needle Bearing in Main

Drive Gear

NOTE

An alternative method is provided which allows the mainshaft
seal to be pressed into place after installation of the main drive
gear. See 

6.7 MAIN DRIVE GEAR AND BEARING, Removal

.

4.

See 

Figure 6-40

. Turn over tool and press in mainshaft

seal using the 0.090 in. step with garter spring side down.

5.

Install spacer.

6.

See 

Figure 6-37

. Turn over the main drive gear in the arbor

press. With the tool at the 0.188 in. step, press inner
bearing until tool contacts gear.

HOME

6-22  2009 Dyna Service: Transmission

1

2

8

7

4

3

6

5

sm03051

1.

12 in. bolt

2.

Cross plate

3.

Screw (2)

4.

Main drive gear bearing

5.

Bearing driver

6.

Nice bearing

7.

Flat washer

8.

Nut

Figure 6-42. Installing Main Drive Gear Bearing (Typical)

Installing Main Drive Gear

NOTE

See 

Figure 6-43

. Make sure new o-ring (4) is installed onto

main drive gear (3). Lubricate o-ring with clean engine oil before
installing drive gear into transmission case.

1.

See 

Figure 6-43

. Apply a light coat of graphite lubricant

to the threads of 8 IN. BOLT (Part No. HD-35316-4A) (1)
and insert through WASHER (Part No. HD-35316-7) (2)
and main drive gear (3). Insert assembly into transmission
case, through main drive gear bearing.

2.

At outside of case, place INSTALLER CUP (Part No. HD-
35316-12) (5), NICE BEARING (6), FLAT WASHER (7)
and NUT (8) over end of bolt.

3.

Tighten nut until main drive gear contacts main drive gear
bearing.

NOTE

See 

Figure 6-44

. In next step, bearing retaining ring must be

installed with the flat side facing the bearing and the opening
in the ninety degree range shown.

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

4.

See 

Figure 6-45

. Install new retaining ring (2).

6

7

8

5

4

2

1

3

sm03052

1.

8 in. bolt

2.

Washer

3.

Main drive gear

4.

O-ring

5.

Installer cup

6.

Nice bearing

7.

Flat washer

8.

Nut

Figure 6-43. Installing Main Drive Gear (Typical)

sm03053

Figure 6-44. Retaining Ring Opening

Installing Main Drive Gear Large Seal

1.

See 

Figure 6-45

. From outside of crankcase, install

PILOT (Part No. HD-47856-2) over end of main drive gear
bearing inner race.

2.

Coat lips of new main drive gear seal with FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUB-
RICANT (Part No. 99851-05, qt).

3.

See 

Figure 6-46

. Place seal over pilot with garter spring

facing bearing, and position seal squarely in end of
crankcase bore.

HOME

6-24  2009 Dyna Service: Transmission

1

2

sm03061

1.

Installer

2.

Nut

Figure 6-48. Installer and Nut

1

3

2

sm03062

1.

Crow's foot wrench

2.

1/2 inch breaker bar

3.

Adjustable wrench

Figure 6-49. Press Seal Into Crankcase

HOME

6-26  2009 Dyna Service: Transmission

6.8

TRANSMISSION CASE

REMOVAL

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)

1.

Disconnect battery, negative (-) cable first.

2.

Drain engine oil. See 

1.5 ENGINE OIL AND FILTER,

Changing Oil and Filter

.

3.

Drain transmission lubricant. See 

1.11 TRANSMISSION

LUBRICANT, Changing Transmission Lubricant

.

4.

Remove starter. See 

7.10 STARTER, Removal

.

5.

Remove transmission assembly. See 

6.6 TRANSMISSION

ASSEMBLY, Removal

.

6.

Remove oil pan. See 

3.30 OIL PAN

.

When lifting a motorcycle using a jack, be sure jack con-
tacts frame tubes only. Never lift by jacking on cross-
members, oil pan, or other housings. Failure to comply
can cause serious damage resulting in the need to perform
major repair work. (00586b)

7.

Position jack across lower frame to support rear of
motorcycle. Slide wooden blocks beneath the crankcase
to support the weight of the engine and transmission
assembly.

8.

Remove rear fork. See 

2.24 REAR FORK, Removal

.

9.

Disconnect vehicle speed sensor (VSS). See

7.24 VEHICLE SPEED SENSOR (VSS), Removal

.

10. Disconnect neutral switch. See 

7.26 NEUTRAL SWITCH,

Removal

.

11. Remove fastener from ground post at top of transmission

case and remove battery negative ring terminal.

12. Move O2 sensor, starter solenoid, neutral switch and VSS

harness out of the way.

13. Mark splines on shift arm and shift shaft to assist in

assembly. Remove shift arm from shift shaft.

14. In a crosswise pattern, remove four fasteners that connect

transmission to engine.

NOTE

See 

Figure 6-10

. Do not use a hammer to remove transmission.

If the transmission sticks or binds on the ring dowels, gently
pry away from crankcase using the indent.

15. Move transmission rearward until two ring dowels in lower

flange are free of crankcase. Remove transmission case
from left side of the motorcycle.

HOME

2009 Dyna Service: Transmission  6-27

1

2

22

21

20

3

4

19

17

14

15

18

16

5

6

7

12

10

13

11

9

8

sm03063

12.

1.

Allen screws

Main drive gear

2.

13.

O-ring

Bearing, inner race

14.

3.

Screw

Transmission case

4.

15.

Bearing

Shifter rod lever

16.

5.

Retaining ring

Bearing

6.

17.

Bevelled retaining ring

Washer

18.

7.

Seal

Oil seal

8.

19.

Sprocket

Sleeve (inside transmission case)

20.

9.

Shifter lever centering spring

Sprocket nut

10.

21.

Oil seal, sixth gear

Shifter pawl lever assembly

22.

11.

Shifter shaft lever spring

Lockplate

Figure 6-50. Transmission Case, Sprocket and Main Drive Gear

INSTALLATION

1.

Install new ground post at top of transmission case.
Tighten ground post until snug.

NOTE

A  new transmission case comes with the shifter shaft sleeve
and seal, centering screw, countershaft needle bearing and
main drive gear bearing and seal installed.

2.

Thoroughly wipe all engine oil from pockets in crankcase
flange.

3.

Install new engine-to-transmission gasket engaging two
index pins in holes of transmission flange.

4.

Verify that transmission dowels are seated. Place trans-
mission case into position behind crankcase. Mate engine
and transmission flanges.

5.

Install and tighten fasteners.

a.

Shorter bolts are installed at the top, longer fasteners
are installed at the bottom. Using a crosswise pattern,
hand tighten fasteners.

b.

See 

Figure 6-51

. Tighten bolts in the sequence shown

to 15 ft-lbs (20.3 Nm) in the same crosswise pattern.

c.

Final tighten bolts to 34-39 ft-lbs (46.1-52.9 Nm).

HOME

6-28  2009 Dyna Service: Transmission

6.

Install oil pan. See 

3.30 OIL PAN

7.

Install rear fork. See 

2.24 REAR FORK, Installation

.

8.

Install shift arm on shift shaft. Align marks made during
disassembly.

9.

Install transmission and side door assembly. See

6.6 TRANSMISSION ASSEMBLY, Installation

.

10. Connect battery ground (-) cable to ground post at top of

transmission case. Tighten securely.

11. Adjust drive belt tension. See 

1.14 REAR BELT

DEFLECTION

.

12. Install primary chaincase. See 

5.5 PRIMARY CHAINCASE

HOUSING

.

13. Install drive components. See 

5.4 DRIVE COMPONENTS

.

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

14. Install primary chaincase cover. See 

5.3 PRIMARY

CHAINCASE COVER

.

15. Install neutral switch and tighten to 120-180 in-lbs (13.6-

20.3 Nm).

16. Install VSS and tighten screw to 84-132 in-lbs (9.5-14.9

Nm)

17. Mate VSS, O2 sensors, starter solenoid and neutral switch

connectors to main harness.

18. Install starter. See 

7.10 STARTER, Installation

19. Install the exhaust system. See 

4.17 EXHAUST SYSTEM

.

20. Clean transmission drain plug and install. Tighten to 14-

21 ft-lbs (19.0-28.5 Nm). Place motorcycle in an upright
position. Fill transmission to proper level with fresh trans-
mission fluid. See 

1.11 TRANSMISSION LUBRICANT

.

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incom-
plete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)

21. Fill primary. See 

1.10 PRIMARY CHAIN, Changing Primary

Chaincase Lubricant

.

22. Fill engine oil. See 

1.5 ENGINE OIL AND FILTER, Chan-

ging Oil and Filter

.

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)

23. Connect battery cables.

4

2

1

3

sm02180

Figure 6-51. Transmission Housing to Crankcase Torque

Sequence

DISASSEMBLY

Shifter Arm Assembly

1.

See 

Figure 6-52

. After removing door assembly, remove

screw (8) and shifter rod lever (9) from the shifter pawl
lever assembly (1).

2.

Remove retaining ring (7), washer (6) and seal (5). Discard
retaining ring and seal. Pull shifter pawl lever assembly
out of the transmission case.

3.

Inspect sleeve (2) inside transmission case.

CLEANING AND INSPECTION

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

1.

Clean all parts in solvent except the case and main drive
gear needle bearings. Blow parts dry with low pressure
compressed air.

NOTE

Never wash the transmission case and needle bearings with
solvent. Normal cleaning methods will wash dirt or other con-
taminants into the bearing case (behind the needles) leading
to bearing failure.

2.

See 

Figure 6-52

. Inspect the shifter pawl lever assembly

(1) for wear. Replace assembly if pawl ends are damaged.
Replace centering spring (3) if elongated.

HOME

2009 Dyna Service: Transmission  6-29

3.

Inspect the shifter spring (4). Replace if the spring fails to
hold the pawl on the cam pins.

4.

Thoroughly clean the oil pan with solvent.

5.

Inspect preformed transmission top cover vent hose for
nicks, cuts or general deterioration. Replace as necessary.
Use low-pressure compressed air to verify that hose and
fitting are unobstructed.

4

1

2

3

5

7

8

11

9

6

10

sm03066

1.

Shifter pawl lever assembly

2.

Sleeve (inside transmission case)

3.

Shift lever centering spring

4.

Shifter shaft lever spring

5.

Seal

6.

Washer

7.

Retaining ring

8.

Screw

9.

Shifter rod lever

10. Washer
11. Screw

Figure 6-52. Shifter Arm Assembly

ASSEMBLY

Countershaft Needle Bearing Replacement

1.

Find a suitable bearing driver 1.25 in. (31.75 mm) in dia-
meter.

2.

From the outside of the transmission case place the needle
bearing open end first next to the bearing bore. Hold the
driver squarely against the closed end of the bearing and
tap the bearing into place. The bearing is properly posi-
tioned when it is driven inward flush with the outside sur-
face of the case or to a maximum depth of 0.030 in. (0.76
mm).

3.

Lubricate the bearing with transmission lubricant.

Shifter Pawl Lever Assembly

1.

See 

Figure 6-52

. Verify that sleeve (2) is inside transmis-

sion case.

2.

See 

Figure 6-53

. Slide shifter lever centering spring (3)

over shaft of shifter pawl lever assembly (2). Align opening
on spring with tab on lever.

3.

Place shifter shaft lever spring (4) on shifter pawl lever
assembly.

NOTE

Do not bend shifter shaft lever spring more than necessary for
assembly.

4.

See 

Figure 6-54

. Insert the assembly into the transmission

case.

5.

See 

Figure 6-55

. Verify that pin sits inside shifter shaft

lever spring.

6.

See 

Figure 6-54

. Install a new seal. Install washer (1) and

a new retaining ring (2).

NOTE

In next step, shifter rod lever must be installed so angle of lever
is toward front of vehicle, one spline from vertical.

7.

See 

Figure 6-52

. Install shifter rod lever (9) on the shifter

pawl lever assembly shaft end using screw (8). Tighten
to 18-22 ft-lbs (24.4-29.8 Nm).

2

1

4

3

sm03067

1.

Pawl (part of shifter pawl lever assembly)

2.

Shifter pawl lever assembly

3.

Shifter lever centering spring

4.

Shifter shaft lever spring

Figure 6-53. Shifter Pawl Lever Assembly

HOME

6-30  2009 Dyna Service: Transmission

4

2

1

3

sm03068

1.

Washer (with seal behind)

2.

Retaining ring

3.

Shifter shaft lever

4.

Pin

Figure 6-54. Shifter Shaft Lever, Exterior View

sm03069

Figure 6-55. Shifter Shaft Lever Spring

HOME

2009 Dyna Service: Transmission  6-31

TABLE OF CONTENTS

SUBJECT

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

PAGE NO.

7.1 FASTENER TORQUE VALUES.................................................................................................7-1
7.2 SPECIFICATIONS: ELECTRICAL.............................................................................................7-3
7.3 ELECTRICAL CADDY...............................................................................................................7-4
7.4 ELECTRONIC CONTROL MODULE (ECM).............................................................................7-6
7.5 SPARK PLUG CABLES.............................................................................................................7-7
7.6 VOLTAGE REGULATOR............................................................................................................7-8
7.7 FUSES AND RELAYS...............................................................................................................7-9
7.8 IGNITION SWITCH/FORK LOCK............................................................................................7-10
7.9 BATTERY TRAY AND BATTERY CABLES..............................................................................7-14
7.10 STARTER..............................................................................................................................7-16
7.11 STARTER SOLENOID...........................................................................................................7-20
7.12 HEADLAMP...........................................................................................................................7-23
7.13 TAIL LAMP.............................................................................................................................7-26
7.14 TURN SIGNALS AND RUNNING LIGHTS............................................................................7-30
7.15 STOP-TAIL-TURN (STT) MODULE: FXDB (DOMESTIC ONLY)...........................................7-34
7.16 TURN SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM).........................................7-35
7.17 CRANK POSITION SENSOR (CKP).....................................................................................7-37
7.18 ALTERNATOR AND STATOR................................................................................................7-38
7.19 FUEL GAUGE........................................................................................................................7-39
7.20 FUEL GAUGE SENDER........................................................................................................7-43
7.21 INSTRUMENTS: FXDC/FXDF...............................................................................................7-46
7.22 INSTRUMENTS: FXDB/FXDL...............................................................................................7-47
7.23 INSTRUMENTS: FXD............................................................................................................7-49
7.24 VEHICLE SPEED SENSOR (VSS).......................................................................................7-50
7.25 INDICATOR LAMPS..............................................................................................................7-51
7.26 NEUTRAL SWITCH...............................................................................................................7-54
7.27 OIL PRESSURE SWITCH.....................................................................................................7-55
7.28 REAR STOPLIGHT SWITCH................................................................................................7-56
7.29 HORN....................................................................................................................................7-57
7.30 ACTIVE EXHAUST................................................................................................................7-58
7.31 MAIN WIRING HARNESS.....................................................................................................7-60
7.32 HANDLEBAR SWITCH ASSEMBLIES..................................................................................7-65
7.33 RIGHT HANDLEBAR SWITCH.............................................................................................7-66
7.34 LEFT HANDLEBAR SWITCH................................................................................................7-72

ELECTRICAL

7.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

7.30 ACTIVE EXHAUST, Installation

4.1-6.8 Nm

36-60 in-lbs

Active exhaust module fasteners

7.9 BATTERY TRAY AND BATTERY
CABLES, Battery Tray

10.8-13.6 Nm

96-120 in-lbs

Battery tray screws

7.17 CRANK POSITION SENSOR (CKP), Installa-
tion

10.2-13.6 Nm

90-120 in-lbs

CKP sensor screw

7.19 FUEL GAUGE, FXD Models

2.0-2.7 Nm

18-24 in-lbs

Console mounting screws

7.25 INDICATOR LAMPS, Installation

2.0-2.7 Nm

18-24 in-lbs

Console mounting screws (FXDB)

7.8 IGNITION SWITCH/FORK LOCK, FXDC, FXDF
Models (Ignition Switch Only)

2.0-2.7 Nm

18-24 in-lbs

Console mounting screws (FXDC, FXDF)

7.21 INSTRUMENTS: FXDC/FXDF, Installation

2.0-2.7 Nm

18-24 in-lbs

Console mounting screws (FXDC/FXDF)

7.25 INDICATOR LAMPS, Installation

2.0-2.7 Nm

18-24 in-lbs

Console mounting screws (FXDC/FXDF)

7.22 INSTRUMENTS: FXDB/FXDL, Installation

2.0-2.7 Nm

18-24 in-lbs

Console to fuel tank fasteners

7.22 INSTRUMENTS: FXDB/FXDL, Installation

2.0-2.7 Nm

18-24 in-lbs

Console to fuel tank fasteners

7.3 ELECTRICAL CADDY, Installation

4.5-6.8 Nm

40-60 in-lbs

Electrical caddy fasteners, front

7.3 ELECTRICAL CADDY, Installation

10.2-12.4 Nm

90-110 in-lbs

Electrical caddy fasteners, top

7.19 FUEL GAUGE, FXD Models

2.03-2.49 Nm

18-22 in-lbs

Fuel gauge trim ring screws

7.21 INSTRUMENTS: FXDC/FXDF, Installation

2.03-2.71 Nm

18-24 in-lbs

Fuel tank trim screws

7.33 RIGHT HANDLEBAR SWITCH, Installation

6.8-9.0 Nm

60-80 in-lbs

Handlebar switch clamp screws

7.34 LEFT HANDLEBAR SWITCH, Installation

6.8-9.0 Nm

60-80 in-lbs

Handlebar switch clamp screws

7.33 RIGHT HANDLEBAR SWITCH, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screws

7.34 LEFT HANDLEBAR SWITCH, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screws

7.12 HEADLAMP, Headlamp Assembly Installation

33.9-40.7 Nm

25-30 ft-lbs

Headlight horizontal adjusting bolt

7.29 HORN, Replacement

13.6-20.3 Nm

10-15 ft-lbs

Horn mounting nut

7.25 INDICATOR LAMPS, Installation

2.0-2.7 Nm

18-24 in-lbs

LED assembly fasteners

7.11 STARTER SOLENOID, Solenoid Contacts

7.3-9.0 Nm

65-80 in-lbs

Long post jam nut

7.26 NEUTRAL SWITCH, Installation

13.6-20.3 Nm

120-180 in-lbs

Neutral switch

7.27 OIL PRESSURE SWITCH, Installation

10.8-16.3 Nm

96-144 in-lbs

Oil pressure switch

7.28 REAR STOPLIGHT SWITCH, Installation

16.3-20.3 Nm

12-15 ft-lbs

Rear stoplight switch

7.14 TURN SIGNALS AND RUNNING
LIGHTS, Rear Lamp Housing Replacement

16.3-21.7 Nm

12-16 ft-lbs

Rear turn signal lamp fastener

7.10 STARTER, Field Coil Assembly

7.9-10.2 Nm

70-90 in-lbs

Solenoid ring terminal nut

7.24 VEHICLE SPEED SENSOR (VSS), Installation

9.5-12.2 Nm

84-108 in-lbs

Speedometer sensor mounting bolt

7.10 STARTER, Field Coil Assembly

10.2-12.4 Nm

90-110 in-lbs

Starter end cover screw

7.10 STARTER, Installation

33.9-36.6 Nm

25-27 ft-lbs

Starter mounting bolts

7.9 BATTERY TRAY AND BATTERY
CABLES, Battery Cables/metric 

7.3-9.6 Nm

65-85 in-lbs

Starter positive terminal nut

7.10 STARTER, Installation

7.3-9.6 Nm

65-85 in-lbs

Starter positive terminal nut

7.10 STARTER, Field Coil Assembly

4.4-7.3 Nm

39-65 in-lbs

Starter thru bolts

7.18 ALTERNATOR AND STATOR, Installation/T27
TORX, use only once 

6.2-8.4 Nm

55-75 in-lbs

Stator screws

HOME

2009 Dyna Service:  Electrical  7-1

NOTES

TORQUE VALUE

FASTENER

7.13 TAIL LAMP, Base Replacement: All But FXDB

4.5-5.4 Nm

40-48 in-lbs

Tail lamp base screws: all but FXDB

7.13 TAIL LAMP, Base Replacement: FXDB

9.5-12.2 Nm

84-108 in-lbs

Tail lamp base screws: FXDB

7.13 TAIL LAMP, Tail Lamp Bulb Replacement:
Standard Style

2.3-2.7 Nm

20-24 in-lbs

Tail lamp lens screws

7.13 TAIL LAMP, Base Replacement: All But FXDB

2.3-2.7 Nm

20-24 in-lbs

Tail lamp lens screws: all but FXDB

7.20 FUEL GAUGE SENDER, Installation

3.1-3.7 Nm

27-33 in-lbs

Top plate fasteners (all but FXD)

7.20 FUEL GAUGE SENDER, Installation

1.7-2.4 Nm

15-21 in-lbs

Top plate fasteners (FXD)

7.9 BATTERY TRAY AND BATTERY
CABLES, Battery Cables

17.6-27.1 Nm

13-20 ft-lbs

Transmission ground stud nut

7.6 VOLTAGE REGULATOR, Installation

6.8-9.0 Nm

60-80 in-lbs

Voltage regulator fasteners

HOME

7-2  2009 Dyna Service:  Electrical

7.2

SPECIFICATIONS: ELECTRICAL

SPECIFICATIONS

Table 7-1. Ignition

DATA

IGNITION

1000 ± 50 RPM

Idle speed

12 mm

Spark plug size

0.038-0.043 in.

Spark plug gap

0.97-1.09 mm

Harley-Davidson

No. 6R12

(no substitute)

Spark plug type

0.5-0.7 ohms

Ignition coil primary resistance

5500-7500 ohms

Ignition coil secondary resistance

Table 7-2. Fuses

AMPS

FUSE

40

Main fuse

15

Brakes

15

Accessory

15

P&A

15

Radio power/siren

15

ECM power

15

Ignition

15

Engine control: active exhaust (HDI only)

15

Lighting

15

Instruments

15

Headlamp

30

ABS

2

P&A ignition

15

Fuel pump

15

Battery

15

Radio memory

Table 7-3. Charging System

DATA

CHARGING SYSTEM

19 amp hour/270 CCA

Battery

16-23 VAC per 1000 RPM

Alternator AC voltage output

0.1-0.2 ohms

Alternator stator coil resistance

14.3-14.7

@

75° F (24° C)

Regulator voltage output @ 3600
RPM

35-50 amps

Regulator amperes @ 3000 RPM

Table 7-4. Starter Specifications

STARTER DATA

3000 RPM (min.) @ 11.5 V

Free speed

90 amp (max.) @ 11.5 V

Free current

200 amp (max.) @ 68°F

Cranking current

8.0 ft-lbs (10.8 Nm) @ 2.4 V

Stall torque

Table 7-5. Starter Service Wear Limits

MM.

IN.

ITEM

11.0

0.443

Brush length (minimum)

0.41

0.016

Commutator runout

28.98

1.141

Commutator diameter (minimum)

0.203

0.008

Commutator mica depth (minimum)

NOTE

The fuse labeled Security provides basic turn signal function-
ality on vehicles without a factory-installed security system. Do
not remove this fuse or use it as a replacement fuse for other
systems.

HOME

2009 Dyna Service:  Electrical  7-3

7.3

ELECTRICAL CADDY

REMOVAL

NOTE

Security siren connector [142] is located under seat.

1.

Remove seat.

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

2.

Disconnect negative battery cable.

3.

See 

Figure 7-1

. Firmly grasp both sides of electrical caddy

cover and pull outward to remove.

4.

See 

Figure 7-2

. Remove relay and fuse panels from

electrical caddy.

a.

Insert small screwdriver into slot located under each
relay/fuse panel.

b.

Using screwdriver, disengage relay/fuse panel from
electrical caddy.

c.

Repeat for other relay/fuse panel.

5.

See 

Figure 7-3

. Disconnect main fuse connector from

electrical caddy (1).

a.

Remove main fuse from connector.

b.

Insert small screwdrivers into slots (4) located on each
side of main fuse.

c.

Using screwdrivers depress tabs of main fuse con-
nector to disengage from electrical caddy.

6.

Depress tab located on electrical caddy securing
TSM/TSSM/HFSM. Pull TSM/TSSM/HFSM from electrical
caddy. Disconnect TSM/TSSM/HFSM connector (2) [30].

7.

Slide data link connector (3) [91] towards front of vehicle
to disengage from electrical caddy.

sm02029

Figure 7-1. Electrical Caddy Cover

sm02538

Figure 7-2. Removing Relay/Fuse Panels

3

2

1

4

sm02539

1.

Electrical caddy

2.

TSM/TSSM/HFSM connector [30]

3.

Data link connector

4.

Main fuse removal slots

Figure 7-3. Electrical Caddy Removal

8.

See 

Figure 7-4

. Disconnect electronic control module

(ECM) connector (2) [78].

9.

Disconnect ignition coil connector [83].

10. Disconnect spark plug cables from coil.

11. Remove front electrical caddy fastener (4).

12. Remove top electrical caddy fasteners (3).

13. Remove wiring from electrical caddy.

14. Remove fasteners securing ECM and ground wire to

electrical caddy.

INSTALLATION

1.

Attach ECM and ground wire to electrical caddy.

2.

Install main fuse connector into rear of electrical caddy.

3.

Install relay and fuse panels into rear of electrical caddy.

4.

Route ECM and data link connector wiring through rear
of electrical caddy past ECM.

HOME

7-4  2009 Dyna Service:  Electrical

5.

See 

Figure 7-5

. Route TSM/TSSM/HFSM wiring through

rear of electrical caddy as shown.

6.

See 

Figure 7-4

. Install but do not tighten electrical caddy

front fastener (4).

7.

Install electrical caddy top fasteners (3). Tighten to 90-110
in-lbs (10.2-12.4 Nm).

8.

Tighten electrical caddy front fastener to 40-60 in-lbs (4.5-
6.8 Nm).

9.

Connect electronic control module (ECM) connector [78].

10. See 

Figure 7-3

. Connect TSM/TSSM/HFSM connector (2)

[30] to TSM/TSSM/HFSM. Slide TSM/TSSM/HFSM into
electrical caddy until tab of caddy engages
TSM/TSSM/HFSM.

11. Install data link connector (3) to electrical caddy as shown.

12. Install main fuse.

13. Attach coil connector [83].

14. Attach spark plug cables. Rear cable is installed on upper

coil tower.

15. Install electrical caddy cover.

16. 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)

17. Install seat.

4

2

1

3

sm02540

1.

Electrical caddy

2.

ECM connector [78]

3.

Top electrical caddy fasteners (2)

4.

Front electrical caddy fastener

Figure 7-4. Electrical Caddy Fasteners

sm02541

Figure 7-5. TSM/TSSM/HSFM Wiring

HOME

2009 Dyna Service:  Electrical  7-5

7.4

ELECTRONIC CONTROL MODULE (ECM)

GENERAL

The electronic control module (ECM) is mounted in the elec-
trical caddy. Refer to the Electrical Diagnostic Manual for
information on the function and testing of the electronic control
module.

NOTE

The electronic control module cannot be repaired. Replace the
unit if it fails.

REPLACEMENT

1.

Follow removal instructions under 

7.3 ELECTRICAL

CADDY

 to remove the electronic control module.

NOTE

After installing ECM, the password learning procedure must
be performed. See the Electrical Diagnostic Manual for this
model.

2.

Follow installation instructions under 

7.3 ELECTRICAL

CADDY

 to install the electronic control module.

sm02542

Figure 7-6. ECM Location

HOME

7-6  2009 Dyna Service:  Electrical

7.5

SPARK PLUG CABLES

REMOVAL

Disconnecting spark plug cable with engine running can
result in electric shock and death or serious injury.
(00464b)

NOTE

When disconnecting spark plug cable, grasp and pull on the
rubber boot at the end of the cable assembly. Do not pull on
the cable portion itself. Pulling on the cable will damage the
cable's carbon core.

1.

Disconnect spark plug cables from ignition coil and spark
plug terminals. Inspect all removed cables for damage.

2.

See 

Figure 7-7

. Remove clips (1) on horn bracket for front

spark plug cable.

INSTALLATION

1.

See 

Figure 7-7

. Connect spark plug cables to ignition coil

and spark plugs. Rear cylinder plug cable attaches to top
coil terminal (4). Fasten boots/caps securely. Tight con-
nections provide the necessary moisture-proof environ-
ment for the ignition coil and spark plug terminals.

2.

Secure front spark plug cable to horn bracket with clips
(1).

3.

Install cable retention clip (2) over spark plug cables. Be
sure clip is 1.5-2.0 in. (38.1-50.8 mm) from spark plug
boots (3).

4

3

3

2

1

sm02544

1.

Horn bracket clips

2.

Cable retention clip

3.

Spark plug boots

4.

Top coil terminal

Figure 7-7. Spark Plug Cable Routing

HOME

2009 Dyna Service:  Electrical  7-7