Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

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360

CHAPTER EIGHT

136

ELECTRICAL PANEL (1999-2000)

Cover

Grommet

Outer plate

Bolt

Washer

Label

Nut

Starter relay (diode)

Mounting bracket

10.

Bolt

11.

Turn signal canceller

module (TSM)

12.

Electrical panel

13.

Nut

14.

Circuit breaker-30

amp

15.

Pop rivet

16.

Screw

17.

Nut

18.

Nut

19.

Bolt

20.

Bank angle sensor

21.

Nut

22.

Bracket

23.

Stand off stud

24.

Decal

25.

Ignition key

26.

Face nut

27.

Ignition switch

28.

Electrical connector

1. When the left turn signal switch is pressed, a mo-

3. When the right turn signal switch is pressed, a

mentary 12 VDC pulse is sent to Pin No. 8 (input)

momentary 12 VDC pulse is sent to Pin No. 7 (in-

on the TSM module. The module responds to this

put) on the TSM module and an output signal at Pin

signal by sending a series of 12 VDC pulses to Pin

No. 3 (output). The remaining signal process is

No. 4 (output) to flash the left front and rear turn

identical to the left turn signal operation.

signal lamps.

2. The TSM module then monitors the number of

Preliminary Troubleshooting

vehicle speed sensor pulses sent from the speed-

ometer sending unit to Pin No. 3. These pulses in-

dicate the distance the motorcycle has traveled.

If one or all of the turn signals do not flash, per-

When the number of speedometer pulses is equal

form the following:

to the quantity preset in the module program, the

1. Remove the lens and check for a defective

turn signal is cancelled.

bulb(s). Replace the bulb(s) if necessary.

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362

CHAPTER EIGHT

2. If the bulb(s) is good, check for one of the fol-

lowing problems:

140

a. Check the bulb socket contacts for corrosion.

Clean the contacts and then recheck. If there

is a problem with corrosion building on the

contacts, wipe the contacts with a dielectric

grease before re-installing the bulb.

b. Check for a broken wire within the circuit.

Repair the wire(s) or connector(s).

c. Check for a loose bulb socket where it is

staked to the housing. If the bulb socket is

loose, replace the light assembly.

d. Check for a poor ground connection. If the

a. Connect a voltmeter positive test lead to the

ground is poor, clean the ground mounting

white/green wire. Connect the negative test

area or replace damaged ground wire(s), as

lead to a bare ground.

required.

b. Spin the rear wheel in the normal direction.

e. Stuck turn signal button.

c. The voltmeter reading should vary from 6-12

3. Remove the TSM or TSSM as described in this

volts to less than 1 volt and back again.

chapter.

d. If the TSM fails this test, replace the TSM and

4. Disconnect the electrical connector from the

repeat Steps 1-3 with a good module.

TSM or TSSM.

5. Check the electrical connectors in the TSM or

TSSM and in the wiring harness for corrosion.

Time Test

Clean off if necessary.

This is an alternate test to the Distance Test, pre-

viously described, to check if the TSM module is

Distance Test

operating correctly. Measure the turn signal ON

time at the four indicated constant speed and time

The turn signal module (TSM) recognizes four

ranges listed in Table 8.

different speed ranges and uses these distances to

If the TSM fails this test, replace the TSM and re-

activate the cancellation action. Refer to the speed

peat with a good module.

and distance ranges listed in Table 7.

1. Ride the motorcycle at the mid-point of speed

range No. 1.

Rider Preference Setting

2. Press and release the right turn button and

closely check the vehicle speed and the odometer at

If the rider desires the turn signals to flash for a

the time the button is released and the time the turn

longer or shorter distance that the pre-set time, per-

signal is cancelled.

form the following:

3. Repeat Step 1 and Step 2 for right and left turns

1. Longer distance cycle: hold the turn signal lon-

at the midpoint of speed ranges No. 2 through No. 4.

ger and release it closer to the turning point.

2. Shorter distance cycle: press the button a second

4. If the distances observed in Steps 1-3 are not cor-

time to cancel the turn signals.

rect, check the following steps:

a. Check the TSM ground connection and mod-

ule pin connections for corrosion.

Turn Signal Module (TSM)

b. Check all lamps and lamp connections.

Removal/Installation

c. Check the vehicle speed sensor (Figure 142)

connections and ground for corrosion.

1. Remove the seat as described in Chapter Thir-

5. Raise the motorcycle with the rear wheel off the

teen.

ground.

2. Turn the ignition switch OFF.

6. At the speedometer electrical connector, per-

3. Remove the electrical panel cover and outer

form the following:

plate as described in this chapter.

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ELECTRICAL SYSTEM

363

141

TURN SIGNAL MODULE (TSM) (1999-2000)

Speedometer

Left turn

signal

switch

light

Module

Right turn

signal

switch

light

1. Module ground to motorcycle

Power

2. 12 VDC input from accessory

circuit breaker

3. Pulsed 12 VDC for flashing

right signal lights

4. Pulsed 12 VDC for flashing

left signal lights

5. Vehicle speed sensor input

W/V

(from speedometer)

6. Not used

W/BN

O/W

7. 12 VDC input from right side

handlebar switch

8. 12 VDC input from left side

handlebar switch

W/G

4. Disconnect the harness connector from the mod-

142

ule.

5. Remove the screw securing the module to the in-

ner panel and remove the module.

6. Install the module by reversing these removal

steps while noting the following:

a. Make sure the electrical connectors are free of

corrosion.

b. Tighten the screw securely.

c. Check that the turn signal and flasher systems

work properly.

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364

CHAPTER EIGHT

TURN SIGNAL MODULE AND

TURN SIGNAL/SECURITY MODULE

143

(2001-ON MODELS)

The turn signal module (TSM) module is an

electronic microprocessor that controls the turn

signals, the four-way hazard flasher and the bank

angle sensor. The turn signal module receives its

information from the speedometer and turn signal

switches. On models so equipped, the security sys-

tem is also included in the TSSM. This TSSM has a

different part number and is not interchangeable

with the TSM.

Manual cancellation

The turn signal module (TSM) or turn signal se-

1. After the turn signal button is depressed, then re-

curity module (TSSM) is located in the electrical

leased, the system begins a 20 count. To cancel the

panel on the left side of the frame.

turn signal from flashing, depress the turn signal

If a problem occurs within either system, a diag-

button a second time.

nostic fault code(s) will be set. The TSM and TSSM

2. If the turn direction is to be changed, depress the

can only be tested with Harley-Davidson diagnostic

opposite turn signal button. The primary signal is

equipment. The following information illustrates

cancelled and the opposite turn signal will flash.

how the systems are designed to operate correctly.

If any portion of the module is inoperative, have the

unit tested by a Harley-Davidson dealership.

Four-way flashing

1. Turn the ignition key to the ON position. On

models so equipped, disarm the security system.

Turn Signal Operation

Press both the right and left turn signal buttons at

the same time. All four turn signals will flash at the

Automatic cancellation

same time.

2. On models with the security system, turn the ig-

NOTE

nition key to the OFF position and arm the security

The TSM/TSSM will not cancel the

system. Press both the right and left turn signal but-

signal before the turn is actually com-

tons at the same time. All four turn signals will now

pleted.

flash at the same time for up to two hours.

3. To cancel the four-way flashing, disarm the se-

1. When the turn signal button is depressed, then

curity system (models so equipped), and press both

released, the system begins a 20 count. As long as

the right and left turn signal buttons at the same

the motorcycle is moving above 7 MPH (11 KPH)

time. The flashing will stop.

the turn signals will always cancel after the 20 bulb

flashes, providing the TSM does not receive any ad-

ditional input.

Bank angle sensor

2. If the motorcycle’s speed drops to 7 MPH (11

The bank angle sensor will automatically shut off

KPH) or less, including stopping, the turn signals

the engine if the motorcycle tilts to more than 45 de-

will continue to flash. The counting will continue

grees from vertical for longer than one second. The

when the motorcycle reaches 8 MPH (13 KPH) and

shutoff will occur even at a very slow speed if the

will automatically cancel when the count total

tilt reaches this angle.

equals 20 bulb flashes.

To restart the motorcycle, return it to a vertical

3. The turn signals will cancel within two seconds

position. Turn the ignition key from OFF to ON,

after the turn of 45 degrees or more is completed

then restart the engine.

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ELECTRICAL SYSTEM

365

Turn Signal Security Module (TSSM)

144

Removal/Installation

1. Remove the seat as described in Chapter Thir-

teen.

2. Turn the ignition switch off.

3. Remove the electrical panel cover and outer

plate as described in this chapter.

4. Remove the TSSM (Figure 143) from the clip

on the inner plate.

5. Disconnect the harness connector from the module.

6. Install the module by reversing these removal

steps while noting the following:

Security System (TSSM) Functions

a. Make sure the electrical connectors are free of

moisture.

b. Make sure the module is secure in its clip.

If a theft attempt is detected and the TSSM is in

c. Check that the turn signal and flasher systems

operation, it will immobilize the starting and igni-

work properly.

tion systems. It will also alternately flash the right

and left turn signals and sound the siren, if so

equipped. The following conditions will activate

SPEEDOMETER SPEED SENSOR

the armed security system.

All models are equipped with an electronic

1. Detecting small motorcycle movement: The turn

speedometer assembly that consists of the speed-

signals will flash three times and the optional siren

ometer, speed sensor and function switch.

will chirp once, then turn off. If the motorcycle is

The speed sensor mounts inside the transmission

not returned to its original position, the warnings

housing, directly over fourth gear.

will reactivate after four seconds. This cycle will re-

peat a maximum of 255 times.

2. Detecting large motorcycle movement: The pre-

Performance Check

vious system will activate for 30 seconds and then

The Harley-Davidson Speedometer Tester must

turn off. If the motorcycle is not returned to its origi-

be used to check the performance of the speedome-

nal position, the warnings will reactivate after ten

ter.

seconds. This cycle may repeat a maximum of ten

times.

NOTE

3. Detects tampering of security lamp circuit: Sys-

This test cannot be used to verify the

tem activates for 30 seconds. The cycle will repeat

calibration of the speedometer and

for each tampering incident.

will not verify the speedometer’s func-

tion to support legal proceedings. The

4. Detecting that a battery ground or ground dis-

test will verify speedometer function

connect has occurred while the system is armed:

when performing service diagnosis or

The siren will sound, if so equipped, but the turn

repair and to verify if the speedometer

signals will not flash.

requires replacement.

NOTE

Speedometer Speed Sensor

Always disarm the optional TSSM

Removal/Installation

prior to disconnecting the battery or

the siren will sound. If the TSSM is in

The speedometer speed sensor mounts on top of

auto-alarming mode, disarm the sys-

the transmission case.

tem with two clicks of the key fob and

disconnect the battery or remove the

1. Remove the seat.

TSSM fuse before the 30-second arm-

2. Disconnect the negative battery cable as de-

ing period expires.

scribed in this chapter.

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366

CHAPTER EIGHT

3. Remove the Allen screw and remove the speed

sensor (Figure 142) from the transmission case.

145

4. Disconnect the three-pin Mini-Deutsch connec-

tor containing one red, one black, and one white

wire.

NOTE

The electrical connector is not shown

in Figure 144 since it is located under

the frame cross-member.

5. Carefully pull the electrical connector out from

under the frame cross-member (Figure 144). Dis-

connect the secondary locks on the Mini-Deutsch

3. Remove the electrical panel cover and outer

connector and disconnect the connector.

plate as described in this chapter.

6. Tie a piece of string to the electrical connector.

4. Unplug the starter relay switch (Figure 145) and

Tie the other end of the string to the frame

remove it from the relay block.

cross-member.

5. To test the switch, refer to Starter Relay Testing

7. Carefully pull the wiring harness and connector

under Electric Starting System in Chapter Two.

out of the frame on the right side. If the wire be-

6. Install by reversing these steps.

comes tight or stuck, do not force it. If necessary,

make a drawing of the wire routing through the

frame. It is easy to forget the routing path after re-

INSTRUMENTS

moving the wire.

Removal/Installation

8. Untie the string from the wiring harness.

(FXD, FXDS-CONV, FXDX, FXDXT, FXDP)

9. Install by reversing these removal steps while

noting the following:

Refer to Figure 146.

a. Tie the string to the wiring harness and con-

1. Remove the seat.

nector.

b. Carefully pull the string, wiring harness and

NOTE

connector through the right side of the frame

Always disarm the optional TSSM

and into position under the seat. Untie and re-

security system prior to disconnect-

move the string.

ing the battery or the siren will

sound.

c. Apply a light coat of dielectric compound to

the electrical connector(s) prior to installing

2. Disconnect the negative battery cable as de-

them.

scribed in this chapter.

d. Apply clean engine oil to the new O-ring on

3. On models so equipped, remove the windshield

the speedometer sensor prior to installation.

or front fairing.

Install the sensor and tighten the Allen screw

4. To remove the speedometer, perform the follow-

to the specification in Table 6.

ing:

a. Remove the two screws securing the

STARTER RELAY SWITCH

backplate (A, Figure 147) and take it off.

REPLACEMENT

b. Depress the tab and disconnect the 12-pin

electrical connector from the back of the

The starter relay switch is mounted inside the

speedometer.

electrical panel.

c. Carefully push the speedometer and front

1. Remove the seat as described in Chapter Thir-

gasket (A, Figure 148) out through the front

teen.

of the meter housing.

2. Disconnect the negative battery cable as de-

d. Remove the front gasket from the speedome-

scribed in this chapter.

ter.

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ELECTRICAL SYSTEM

369

5. To remove the tachometer, perform the follow-

ter and tachometer to the underside of the

ing:

console.

a. Remove the two screws securing the

d. Depress the tab and disconnect the 12-pin

backplate (B, Figure 147) and take it off.

electrical connector from the back of the

b. Depress the tab and disconnect the 6-pin elec-

speedometer.

trical connector from the back of the tachom-

e. Carefully remove the speedometer and gasket

eter.

out through the front of the console.

c. Carefully push the tachometer and front gas-

f. Remove the gasket from the speedometer.

ket (B, Figure 148) out through the front of

5. To remove the tachometer, perform the follow-

the meter housing.

ing:

d. Remove the front gasket from the tachometer.

a. Perform Steps 4a-4c of speedometer removal.

6. Store the meters in a safe place.

b. Remove the T15 Torx screw securing the wir-

7. Remove the rear gasket(s) from the meter hous-

ing harness clip to the backside of the ta-

ing. They are identical with the same part number.

chometer.

NOTE

c. Gently pry on each end of the 6-pin electrical

If necessary, apply alcohol or glass

connector and disconnect it from the backside

cleaner to the gasket surfaces to ease

of the tachometer.

installation of the meters.

d. Carefully remove the tachometer and gasket

out through the front of the console.

8. If removed, install the front gasket onto the me-

ter and install it into the meter housing. Press firmly

e. Remove the gasket from the tachometer.

until the meter is correctly seated.

6. If removed, install the gasket onto the perimeter

9. Connect the electrical connector to the backside

of the console where it mounts onto the fuel tank.

of the meter. Route the electrical wiring through the

7. To install the speedometer, perform the follow-

slot in the backside of the meter housing.

ing:

10. Install the rear gasket onto the meter and hous-

a. Install the gasket onto the console.

ing.

b. Install the speedometer onto the console and

11. Install the backplate and tighten the screws se-

gasket. Make sure the speedometer is seated

curely.

correctly onto the gasket.

12. On models so equipped, install the windshield

c. Connect the 12-pin electrical connector onto

or front fairing.

the back of the speedometer.

8. To install the tachometer, perform the following:

Removal/Installation

a. Install the gasket onto the console.

(FXDL)

b. Install the tachometer onto the console and

gasket. Make sure the tachometer is seated

Refer to Figure 149.

correctly onto the gasket.

1. Remove the seat as described in Chapter Thir-

c. Install and push down and install the 6-pin

teen.

electrical connector onto the back of the ta-

2. Disconnect the negative battery cable as de-

chometer.

scribed in this chapter.

3. Cover the fuel tank surrounding the instrument

d. Install the wire harness and clip to the back-

assembly with towels to protect the finish.

side of the tachometer. Install the T15 Torx

screw securing the wiring harness clip and

4. To remove the speedometer, perform the follow-

tighten securely.

ing:

a. Remove the two Allen screws securing the

9. Install the mounting bracket to the underside of

console assembly to the fuel tank.

the console. Align the bolt holes in the mounting

b. Lift the console assembly up, turn it over and

bracket and the speedometer and tachometer.

place it on the fuel tank towels.

10. Install the four Allen screws securing the

c. Remove the four Allen screws and remove

mounting bracket to the backside of the speedome-

the mounting bracket securing the speedome-

ter and tachometer.

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370

CHAPTER EIGHT

11. Check that there will be no binding with the

150

INSTRUMENTS (FXDWG)

wiring harness and the bracket after the console is

installed onto the fuel tank.

12. Carefully turn the console assembly over and

position it on the fuel tank aligning the screw holes.

13. Install the two Allen screws securing the con-

sole assembly to the fuel tank and tighten securely.

14. Connect the negative battery cable as described

in this chapter.

15. Install the seat.

Removal/Installation

(FXDWG)

Refer to Figure 150.

1. Remove the seat as described in Chapter Thir-

teen.

2. Disconnect the negative battery cable as de-

scribed in this chapter.

3. Cover the fuel tank surrounding the instrument

assembly with towels to protect the finish.

4. Remove the acorn nut securing the console as-

sembly to the set screw on the fuel tank.

5. Lift the console assembly up, turn it over and

place it on the fuel tank towels.

6. Depress the tab and disconnect the

12-pin

electrical connector from the back of the speed-

ometer.

7. Unscrew the rubber boot from the reset switch

on the left side of the console.

8. Remove the reset switch from the side of the

console.

9. Carefully pry and raise the three tabs and the

speedometer to release the back clamp from the

speedometer.

Speedometer

Gasket

10. Remove the speedometer and gasket out

Trim plate

through the front of the console.

Indicator light bezel

11. Remove the gasket from the speedometer.

Acorn nut

12. Install the gasket onto the speedometer.

Console

Boot

13. Install the speedometer into the console.

Reset switch

14. Press on the three tabs and push onto the back-

Set screw

side of the speedometer until they are engaged.

10.

Clip

11.

Trim piece

15. Insert the reset switch through the side in the

12.

Ignition switch and key

console and install the rubber boot.

13.

Cage nut

16. Connect the 12-pin electrical connector onto

14.

Clamp

the back of the speedometer.

15.

Cable strap

17. Carefully turn the console assembly over and

16.

Screw

17.

Indicator light panel

position it on the fuel tank aligning the set screw

with the console hole.

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ELECTRICAL SYSTEM

371

151

Police accessory¹

Instruments

Siren¹

Security

Ignition

Pursuit

Accessories

Lights

P&A¹

15A

1. FXDP Dyna Police models only.

2. FXDP turn signal use only. Security not

available on FXDP models.

varies, depending on the model. The fuse ratings are

152

listed in Table 1. Refer to Figure 151 for fuse loca-

tion on the panel.

All fuses are located on a single panel within the

electrical panel. If there is an electrical failure, first

check for a blown fuse. A blown fuse will have a

break in the element (Figure 152).

Whenever the fuse blows, find out the reason for

the failure before replacing the fuse. Usually, the

trouble is a short circuit in the wiring. This may be

caused by worn-through insulation or a discon-

nected wire shorted to ground. Check the circuit the

fuse protects.

18. Install the acorn nut securing the console as-

sembly to the fuel tank and tighten securely.

19. Connect the negative battery cable as described

Fuse Replacement

in this chapter.

20. Install the seat.

1. Remove the seat as described in Chapter Thir-

teen.

FUSES

NOTE

Always disarm the optional TSSM se-

All models are equipped with a series of fuses to

curity system prior to disconnecting

protect the electrical system. The number of fuses

the battery or the siren will sound.

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372

CHAPTER EIGHT

2. Disconnect the negative battery cable as de-

scribed in this chapter.

153

3. Remove the electrical panel cover as described

in this chapter.

4. Locate the blown fuse (Figure 153) and install a

new one of the same amperage.

NOTE

Always carry spare fuses.

CIRCUIT BREAKER

All models use a single circuit breaker to protect

the electrical circuits. Table

1 lists the circuit

154

breaker rating for the different models.

Whenever a failure occurs in any part of the

electrical system, the circuit breaker is

self-resetting and will automatically return power

to the circuit when the electrical fault is found and

corrected.

CAUTION

If the electrical fault is not found and

corrected, the circuit breaker will cycle

on and off continuously. This will cause

the motorcycle to run erratically.

Disconnect

the

negative

battery

cable

de-

Usually the trouble to a short circuit is found in

scribed in this chapter.

the wiring connected to the circuit breaker.

3. Remove the electric panel cover and inner panel

The circuits protected by the circuit breaker can

as described in this chapter.

be determined by following the wiring diagrams at

NOTE

the end of the book.

Record the number of wires and

Do not consider a tripped circuit breaker as just a

their color and to which terminal

minor annoyance; it indicates that something is

they are connected. The wires must

wrong in the electrical system that must be cor-

be reinstalled onto the correct termi-

rected immediately.

nal.

4. Remove the nuts and wire connections at the cir-

Replacement

cuit breaker (Figure 154).

5. Remove the circuit breaker from the mounting

The circuit breaker is located inside the electrical

bracket on the inner panel.

panel.

6. Install the circuit breaker by reversing these

1. Remove the seat as described in Chapter Thir-

steps.

teen.

NOTE

DIAGNOSTIC TROUBLE CODES

Always disarm the optional TSSM se-

curity system prior to disconnecting

Refer to Ignition System in Chapter Two to re-

the battery or the siren will sound.

trieve the diagnostic trouble codes.

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ELECTRICAL SYSTEM

373

Table 1 ELECTRICAL SPECIFICATIONS

Battery

12 volts, 19 amp hour

Alternator

AC voltage output

16-20 VAC per 1000 rpm

Stator coil resistance

0.1-0.2 ohm

Regulator

Voltage output @ 3600 rpm

14.3-14.7 @ 75° F (24° C)

Amperes at 3600 rpm

32 amp

Ignition coil

Primary resistance

0.5-0.7 ohm

Secondary resistance

5500-7500 ohms

Spark plug cable resistance

Front cylinder cable

4700-11230 ohms

Rear cylinder cable

1812-4375 ohms

Circuit breaker

FXDP

40 amp

All models except FXDP

30 amp

Fuses

Ignition fuse

15 amp

Lighting fuse

15 amp

Accessory fuse

15 amp

Instrument fuse

15 amp

Security system*

15 amp

*Models so equipped.

Table 2 MAINTENANCE FREE BATTERY VOLTAGE READINGS

State of Charge

Voltage reading

100%

13.0-13.2

75%

12.8

50%

12.5

25%

12.2

12.0 volts or less

Table 3 BATTERY CHARGING RATES/TIMES (APPROXIMATE)

% of

3 amp

6 amp

10 amp

20 amp

Voltage

Charge

Charger

12.8

100%

12.6

75%

1.75 hours

50 minutes

30 minutes

15 minutes

12.3

50%

3.5 hours

1.75 hours

1 hour

30 minutes

12.0

25%

5 hours

2.5 hours

1.5 hours

45 minutes

11.8

6 hours and

3 hours and

2 hours

1 hour

40 minutes

20 minutes

Table 4 STARTER MOTOR SPECIFICATIONS

Minimum free speed

3000 rpm @ 11.5 volts

Maximum free current

90 amp @ 11.5 volts

Cranking current

200 amp maximum @ 68° F (20° C)

Brush length (minimum)

0.433 in. (11.0 mm)

Commutator diameter (minimum)

1.141 in. (28.98 mm)

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374

CHAPTER EIGHT

Table 5 REPLACEMENT BULBS

Item

Size (all 12 volt) × quantity

Headlamp

55/60

Position lamp*

3.9

Indicator lamps

FXDL

1.1 x 4

FXDP

2.1 x 4

All models except FXDL and FXDP

2.2 x 3

Fuel gauge

FXDL, FXDWG

2.7

FXD, FXDX, FXDX-CONV, FXDXT

3.7

FXDP

Front turn signal/running light

27/7 x 2

Front turn signal*

21 x 2

Rear turn signal

27 x 2

Rear turn signal*

21 x 2

Tail/brake lamp

7/27

Tail/brake lamp*

5/21

*Indicates bulb specification for HD International models.

Table 6 ELECTRICAL SYSTEM TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N·m

Alternator stator

Torx screws

30-40

3-5

Camshaft position sensor

(1999-2000)

Inspection cover screws

20-30

2-3

Sensor screw

20-30

2-3

Crankshaft position

sensor (CKP)

Allen screw

90-120

10-14

Fuel gauge sending unit

plate screws

Fuel tank

Console nut

80-100

9-11

Mounting bolt

10-18

14-24

Handlebar switch

housing screw

35-45

4-5

Headlight

Mounting block bolt

25-30

34-41

Mounting nut

120-180

14-20

Mounting screw

25-30

34-41

Shade bolt

120-144

14-16

Horn mounting nut

110

Ignition coil bolts

24-72

3-8

Ignition module screw

15-21

2-3

Instrument cluster bolt

12-18

16-24

Jackshaft lockplate bolt

84-108

9-12

MAP sensor screw

20-30

2-3

Speedometer sensor

mounting bolt

84-108

9-12

Starter

Mounting bolts

13-20

18-27

Positive terminal nut

65-80

7-9

(continued)

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ELECTRICAL SYSTEM

375

Table 6 ELECTRICAL SYSTEM TORQUE SPECIFICATIONS (continued)

Item

ft.-lb.

in.-lb.

N·m

Starter jackshaft bolt

84-108

9-12

Switches

Neutral

120-180

14-20

Oil pressure

96-120

11-14

Rear stop light

96-120

11-14

Tail/brake light

Base screws

40-48

4-5

Lens screws

20-24

2-3

Voltage regulator screws

60-80

7-9

Table 7 TURN SIGNAL SPEED AND DISTANCE TEST

Range

MPH

0-34

35-44

45-60

61+

KMH

0-56

56-71

72-97

98+

Feet

221

339

680

1051

Miles

0.04

0.06

0.13

0.20

Meters

103

207

320

Table 8 TURN SIGNAL SPEED AND TIME TEST

Constant speed

Signal ON time

MPH

KMH

in seconds

5-7

8-10

105

10-12

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CHAPTER NINE

WHEELS, HUBS AND TIRES

This chapter describes disassembly and repair of

the front and rear wheels, hubs and tire service. For

routine maintenance, see Chapter Three.

Tables 1-3 are at the end of the chapter.

MOTORCYCLE STANDS

Many procedures in this chapter require that the

front or rear wheel be lifted off the ground. To do

this, a quality motorcycle front end stand (Figure

1), swing arm stand, or suitable size jack is required.

Before purchasing or using a stand, check the man-

ufacturer’s instructions to make sure the stand will

work with the Dyna Glide model being worked on.

If any adjustments or accessories are required for

the motorcycle and/or stand, perform the necessary

adjustments or install the correct parts before lifting

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WHEELS, HUBS AND TIRES

377

the motorcycle. When using the motorcycle stand,

have an assistant standing by to help. Some means

to tie down one end of the motorcycle may also be

required. After lifting the motorcycle on a stand,

make sure the motorcycle is properly supported be-

fore walking away from it.

FRONT WHEEL

Removal

1. Support the motorcycle with the front wheel off

the ground. See Motorcycle Stands in this chapter.

NOTE

On models with dual front calipers,

both calipers must be removed to re-

move the front wheel.

2A. On 1999 models, remove the caliper mounting

bolts (Figure 2) and remove the caliper(s) as de-

scribed in Chapter Twelve.

2B. On 2000-on models, remove the caliper mount-

ing bolts (Figure 3) and remove the caliper(s) as de-

scribed in Chapter Twelve.

NOTE

Place a plastic or wooden spacer be-

tween the brake pads in place of the

disc. Then, if the brake pedal is inad-

vertently depressed, the pistons will

not be forced out of the caliper. If this

occurs, disassemble the caliper to re-

seat the pistons.

3. On the left side, remove the axle nut (Figure 4),

lockwasher and flat washer (Figure 5).

4A. On all models except FXDWG, loosen the front

axle pinch bolt (A, Figure 6).

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378

CHAPTER NINE

4B. On FXDWG models, loosen the nuts on the

fork slider cap.

NOTE

On some models, the wheel spacers

are different. Identify the spacers be-

fore removing them.

5. Prior to removing the front axle, note the loca-

tion of the right side spacer (Figure 7) and left side

spacer (Figure 8). The spacer must be reinstalled on

the correct side during installation.

6. Insert a drift or screwdriver into the hole (Figure

9) in the end of the front axle (B, Figure 6). With-

draw the front axle from the fork sliders and front

wheel. Remove the tool from the axle.

7. Pull the wheel away from the fork sliders and re-

move it.

CAUTION

Do not set the wheel down on the

brake disc surface, as it may be dam-

aged.

8. Inspect the front wheel assembly as described in

this chapter.

Installation

1. Clean the axle in solvent and dry thoroughly.

Make sure the axle bearing surfaces on both fork

sliders and the axle are free of burrs and nicks.

2. Apply an antiseize lubricant to the axle shaft

prior to installation.

3. If the oil seals or bearings were replaced, con-

firm front axle spacer alignment as described under

Front Hub in this chapter.

4. Install the left side and right side axle spacers in

the wheel. The left side axle spacer is longer than

the right side spacer.

5. Install the wheel between the fork sliders and in-

stall the axle from the right side (Figure 9).

6. Check that axle spacers are installed correctly.

Refer to Figure 7 for the right side and to Figure 8

for the left side.

7. Install the flat washer, lockwasher (Figure 5)

and axle nut (Figure 4) finger-tight. Check that axle

spacers are installed correctly.

8A. On all models except FXDWG, tighten the front

axle pinch bolt (A, Figure 6) to the specification in

Table 2.

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WHEELS, HUBS AND TIRES

379

8B. On FXDWG models, tighten the nuts on the

Axial

fork slider cap to the specification in Table 2.

9. Insert a drift or screwdriver into the hole (Figure

9) in the end of the front axle (B, Figure 6) to keep it

from rotating.

10. Tighten the front axle nut (Figure 4) to the

specification in Table 2.

11. Remove the tool used in Step 8 from the front

axle.

12. Check that the front wheel is centered between

the fork sliders. If not, check the position of the left

and right axle spacers.

13. On 1999 models, perform the Front Wheel

Radial

Bearing End Play Check in this chapter.

14. Install the front brake caliper(s) as described in

Chapter Twelve.

15. With the front wheel off the ground, rotate it

several times and apply the front brake to seat the

brake pads against the disc(s).

16. Remove the stand and lower the front wheel

onto the ground.

Inspection

Replace any worn or damaged parts as described

in this section.

1. On 1999 models, inspect the oil seals (Figure

10) for excessive wear, hardness, cracks or other

damage. If necessary, replace the seals as described

under Front and Rear Hubs in this chapter.

2. Turn each bearing inner race by hand. The bear-

ing must turn smoothly. Some axial play (end play)

is normal, but radial play (side play) must be negli-

gible. See Figure 11. If one bearing is damaged, re-

place both bearings as a set. Refer to Front and Rear

Hubs in this chapter.

3. Clean the axle and axle spacers in solvent to re-

move all grease and dirt. Make sure the axle contact

surfaces are clean and free of dirt and old grease.

4. Check the axle runout with a set of V-blocks and

dial indicator (Figure 12).

5. Check the spacers for wear, burrs and damage.

Replace as necessary.

6. Check the brake disc bolts (Figure 13) for tight-

ness. To service the brake disc, refer to Chapter

Twelve.

7. Check wheel runout and spoke tension as de-

scribed in this chapter.

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 19