2009 Harley Davidson Dyna Models Service Manual – PDF DOWNLOAD

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2009 Harley-Davidson Dyna Models Service Manual – PDF DOWNLOAD

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DESCRIPTION:

2009 Harley-Davidson Dyna Models Service Manual – PDF DOWNLOAD

ABOUT THIS MANUAL
GENERAL:

• This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair.
• Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.

HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Drive
6 Transmission
7 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Glossary

• Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
• For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
• For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
• A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.

TABLE OF CONTENTS:

2009 Harley-Davidson Dyna Models Service Manual – PDF DOWNLOAD

FOREWORD...........................................................  7
TABLE OF CONTENTS..................................................  9
1. MAINTENANCE..................................................... 21
	1.1 FASTENER TORQUE VALUES..................................... 23
		Fastener Torque Values in this Chapter..................... 23
	1.2 GENERAL.................................................... 25
		Servicing a New Motorcycle................................. 25
		Safe Operating Maintenance................................. 25
		Shop Practices............................................. 25
		Repair and Replacement Procedures.......................... 26
		Cleaning................................................... 27
		Tool Safety................................................ 27
	1.3 MAINTENANCE SCHEDULE....................................... 29
		General.................................................... 29
	1.4 FUEL AND OIL............................................... 32
		Fuel....................................................... 32
		Gasoline Blends............................................ 32
		Engine Lubrication......................................... 32
		Winter Lubrication......................................... 33
	1.5 ENGINE OIL AND FILTER...................................... 34
		Checking and Adding Oil.................................... 34
		Changing Oil and Filter.................................... 35
	1.6 BULB REQUIREMENTS.......................................... 37
		General.................................................... 37
	1.7 BRAKES..................................................... 38
		Fluid Inspection........................................... 38
		Rear Pedal Height.......................................... 38
	1.8 AIR CLEANER AND EXHAUST SYSTEM............................. 40
		Removal.................................................... 40
		Installation............................................... 40
		Exhaust System Leak Check.................................. 41
	1.9 TIRES AND WHEELS........................................... 42
		Tires...................................................... 42
		Tire Replacement........................................... 42
		Wheel Bearings............................................. 43
		Wheel Spokes............................................... 43
	1.10 PRIMARY CHAIN............................................. 44
		General.................................................... 44
		Changing Primary Chaincase Lubricant....................... 44
	1.11 TRANSMISSION LUBRICANT.................................... 46
		Changing Transmission Lubricant............................ 46
	1.12 CLUTCH.................................................... 47
		Adjustment................................................. 47
	1.13 REAR BELT AND SPROCKETS................................... 49
		General.................................................... 49
		Cleaning................................................... 49
		Inspection................................................. 49
	1.14 REAR BELT DEFLECTION...................................... 51
		Inspection................................................. 51
		Adjustment................................................. 52
	1.15 THROTTLE CABLES........................................... 53
		Cable Inspection, Lubrication and Adjustment............... 53
	1.16 BLEEDING BRAKES........................................... 54
		General.................................................... 54
		Procedure.................................................. 54
	1.17 BRAKE PADS AND DISCS...................................... 55
		Inspection................................................. 55
		Brake Pad Replacement...................................... 55
	1.18 BATTERY MAINTENANCE....................................... 58
		General.................................................... 58
		Cleaning and Inspection.................................... 59
		Voltmeter Test............................................. 59
		Charging Battery........................................... 59
		Disconnection and Removal.................................. 60
		Storage.................................................... 61
		Installation and Connection................................ 61
	1.19 SUSPENSION ADJUSTMENTS.................................... 63
		Rear Shock Preload Adjustment.............................. 63
	1.20 SPARK PLUGS............................................... 64
		Inspection................................................. 64
		Spark Plug Cable Inspection................................ 64
	1.21 STEERING HEAD BEARINGS.................................... 66
		Adjustment................................................. 66
		Lubrication................................................ 66
	1.22 FRONT FORK OIL............................................ 67
		Replacing Fork Oil......................................... 67
	1.23 CABLE AND CHASSIS LUBRICATION............................. 68
		General.................................................... 68
		Cables and Hand Levers..................................... 68
		Jiffy Stand................................................ 68
	1.24 HEADLAMP ALIGNMENT........................................ 69
		Headlamp Alignment......................................... 69
		Adjustment................................................. 69
	1.25 CRITICAL FASTENERS........................................ 71
		Inspection................................................. 71
	1.26 ENGINE MOUNTS............................................. 72
		Inspection................................................. 72
	1.27 STORAGE................................................... 73
		General.................................................... 73
		Placing in Storage......................................... 73
		Removal from Storage....................................... 73
	1.28 TROUBLESHOOTING........................................... 75
		General.................................................... 75
		Engine..................................................... 75
		Lubrication System......................................... 76
		Electrical System.......................................... 76
		Transmission............................................... 77
		Handling................................................... 77
		Brakes..................................................... 77
2. CHASSIS......................................................... 79
	2.1 FASTENER TORQUE VALUES..................................... 81
		Fastener Torque Values in this Chapter..................... 81
	2.2 SPECIFICATIONS............................................. 84
		Specifications............................................. 84
	2.3 VEHICLE IDENTIFICATION NUMBER (V.I.N.)..................... 87
		General.................................................... 87
	2.4 FRONT WHEEL................................................ 89
		Removal.................................................... 89
		Disassembly................................................ 89
		Cleaning and Inspection.................................... 92
		Assembly................................................... 92
		Installation............................................... 93
	2.5 REAR WHEEL................................................. 95
		Removal.................................................... 95
		Disassembly................................................ 95
		Cleaning and Inspection.................................... 96
		Assembly................................................... 96
		Installation............................................... 97
	2.6 SEALED WHEEL BEARINGS...................................... 98
		Inspection................................................. 98
		Removal.................................................... 98
		Installation............................................... 99
	2.7 WHEEL LACING: 17 INCH RIM..................................101
		General....................................................101
		Procedure..................................................101
	2.8 WHEEL LACING: 19 INCH RIM..................................104
		Procedure..................................................104
	2.9 WHEEL LACING: 21 INCH RIM..................................108
		General....................................................108
		Procedure..................................................108
	2.10 TRUING LACED WHEELS.......................................111
		General....................................................111
		Lateral Truing.............................................111
		Radial Truing..............................................112
	2.11 CHECKING CAST WHEEL RUNOUT................................114
		General....................................................114
		Lateral Runout.............................................114
		Radial Runout..............................................114
	2.12 VEHICLE ALIGNMENT.........................................115
		Inspection.................................................115
	2.13 FRONT BRAKE MASTER CYLINDER...............................117
		General....................................................117
		Removal and Disassembly....................................117
		Cleaning and Inspection....................................119
		Assembly and Installation..................................119
	2.14 FRONT BRAKE CALIPER.......................................121
		Removal....................................................121
		Disassembly................................................121
		Cleaning, Inspection and Repair............................123
		Assembly...................................................124
		Installation...............................................124
	2.15 REAR BRAKE MASTER CYLINDER................................126
		General....................................................126
		Removal....................................................126
		Disassembly................................................127
		Cleaning and Inspection....................................128
		Assembly...................................................128
		Installation...............................................128
	2.16 REAR BRAKE CALIPER........................................130
		Removal....................................................130
		Disassembly................................................130
		Cleaning, Inspection and Repair............................132
		Assembly...................................................133
		Installation...............................................133
	2.17 TIRES.....................................................135
		General....................................................135
		Removal....................................................135
		Cleaning, Inspection and Repair............................136
		Installation...............................................136
	2.18 FRONT FORK................................................138
		Removal....................................................138
		Disassembly................................................138
		Cleaning and Inspection....................................141
		Assembly...................................................141
		Installation...............................................142
	2.19 STEERING HEAD.............................................143
		Removal....................................................143
		Inspection.................................................144
		Disassembly................................................144
		Assembly...................................................145
		Installation...............................................145
	2.20 BELT GUARD................................................146
		Removal....................................................146
		Installation...............................................146
	2.21 DEBRIS DEFLECTOR..........................................147
		Removal....................................................147
		Installation...............................................147
	2.22 THROTTLE CONTROL..........................................148
		Removal/Disassembly........................................148
		Cleaning and Inspection....................................148
		Assembly/Installation......................................148
		Throttle Cable Routing.....................................148
	2.23 REAR SHOCK ABSORBERS......................................150
		General....................................................150
		Removal....................................................150
		Inspection.................................................150
		Installation...............................................150
	2.24 REAR FORK.................................................151
		Removal....................................................151
		Disassembly................................................152
		Cleaning and Inspection....................................152
		Assembly...................................................152
		Installation...............................................152
	2.25 CLUTCH CONTROL............................................153
		Removal....................................................153
		Installation...............................................153
	2.26 HANDLEBARS: ALL BUT FXDB/FXDF.............................154
		Removal....................................................154
		Installation...............................................155
	2.27 HANDLEBARS: FXDB/FXDF.....................................157
		Removal....................................................157
		Installation...............................................158
	2.28 FRONT FENDER..............................................160
		Removal....................................................160
		Installation...............................................160
	2.29 REAR FENDER...............................................161
		General....................................................161
		FXDF.......................................................162
		FXD, FXDC, and FXDL Models.................................162
		FXDB Models................................................162
	2.30 SEAT......................................................164
		Removal....................................................164
		Installation...............................................164
	2.31 JIFFY STAND...............................................165
		Cleaning...................................................165
		Sensor (HDI Models)........................................165
		Removal....................................................166
		Installation...............................................167
	2.32 ENGINE MOUNTS.............................................168
		Removal....................................................168
		Installation...............................................168
3. ENGINE..........................................................171
	3.1 FASTENER TORQUE VALUES.....................................173
		Fastener Torque Values in this Chapter.....................173
	3.2 SPECIFICATIONS.............................................175
		Specifications.............................................175
	3.3 SERVICE WEAR LIMITS........................................177
		General....................................................177
	3.4 ENGINE OIL FLOW............................................179
		Oil Feed...................................................179
		Top End....................................................179
		Bottom End.................................................181
		Oil Return.................................................183
	3.5 OIL PUMP OPERATION.........................................185
		General....................................................185
		Operation..................................................185
	3.6 BREATHER OPERATION.........................................187
		General....................................................187
	3.7 OIL PRESSURE...............................................188
		Oil Pressure Indicator Lamp................................188
		Checking Oil Pressure......................................188
	3.8 TROUBLESHOOTING............................................189
		Diagnosing Valve Train Noise...............................189
		Compression Test...........................................189
		Cylinder Leakdown Test.....................................189
		Diagnosing Smoking Engine or High Oil Consumption..........190
	3.9 HOW TO USE THIS SECTION....................................191
		Top End Repair.............................................191
		Bottom End Repair..........................................191
		Typical Symptoms...........................................191
	3.10 TOP END SERVICE...........................................192
		Engine in Chassis..........................................192
		Engine Removed from Chassis................................193
	3.11 BOTTOM END SERVICE........................................194
		Engine in Chassis..........................................194
		Engine Removed From Chassis................................195
	3.12 STRIPPING MOTORCYCLE FOR SERVICE..........................196
		Procedure..................................................196
	3.13 ASSEMBLING MOTORCYCLE AFTER SERVICE.......................197
		Procedure..................................................197
	3.14 REMOVING ENGINE FROM CHASSIS..............................198
		Procedure..................................................198
	3.15 INSTALLING ENGINE IN CHASSIS..............................199
		Procedure..................................................199
	3.16 TOP END OVERHAUL: DISASSEMBLY.............................201
		General....................................................201
		Rocker Covers..............................................201
		Rocker Arm Support Plate...................................201
		Push Rods, Lifters and Covers..............................203
		Cylinder Head..............................................204
		Cylinder...................................................205
		Piston.....................................................205
	3.17 TOP END OVERHAUL: ASSEMBLY................................207
		General....................................................207
		Piston.....................................................207
		Cylinder...................................................208
		Cylinder Head..............................................210
		Push Rods, Lifters and Covers..............................214
		Rocker Arm Support Plate...................................215
		Breather Assembly..........................................216
	3.18 BOTTOM END OVERHAUL: DISASSEMBLY..........................218
		General....................................................218
		Cam Support Plate and Cover................................218
		Crankcase..................................................220
	3.19 BOTTOM END OVERHAUL: ASSEMBLY.............................222
		General....................................................222
		Crankcase..................................................222
		Cam Support Plate and Cover................................224
	3.20 BREATHER ASSEMBLY.........................................229
		Removal Overview...........................................229
		Disassembly................................................229
		Cleaning and Inspection....................................229
		Assembly...................................................229
		Installation Overview......................................229
	3.21 ROCKER ARM SUPPORT PLATE..................................230
		Removal Overview...........................................230
		Disassembly................................................230
		Cleaning and Inspection....................................230
		Assembly...................................................232
		Installation Overview......................................232
	3.22 PUSH RODS, LIFTERS AND COVERS.............................234
		Removal Overview...........................................234
		Disassembly................................................234
		Cleaning and Inspection....................................234
		Lifter Inspection..........................................235
		Assembly...................................................235
		Installation Overview......................................236
	3.23 CYLINDER HEAD.............................................237
		Removal Overview...........................................237
		Disassembly................................................237
		Cleaning...................................................238
		Inspection.................................................239
		Valve Guide Replacement....................................240
		Valve and Seat Refacing....................................244
		Assembly...................................................246
		Installation Overview......................................247
	3.24 CYLINDER..................................................248
		Removal Overview...........................................248
		Cleaning...................................................248
		Inspection.................................................249
		Deglazing Cylinder.........................................250
		Boring and Honing Cylinder.................................251
		Installation Overview......................................251
	3.25 PISTON....................................................252
		Removal Overview...........................................252
		Disassembly................................................252
		Cleaning...................................................252
		Inspection.................................................253
		Assembly...................................................254
		Installation Overview......................................256
	3.26 CAM SUPPORT PLATE AND COVER...............................257
		Removal Overview...........................................257
		Camshafts..................................................257
		Oil Pressure Relief Valve..................................259
		Cam Needle Bearings........................................259
		Cleaning and Inspection....................................262
		Installation Overview......................................262
	3.27 OIL PUMP..................................................263
		Removal Overview...........................................263
		Cleaning and Inspection....................................263
		Installation Overview......................................263
	3.28 CRANKCASE.................................................264
		Removal Overview...........................................264
		Right Crankcase Half.......................................264
		Left Crankcase Half........................................265
		Sprocket Shaft Bearing Inner Race..........................268
		Cylinder Studs.............................................270
		Pipe Plug and Oil Fittings.................................271
		Cleaning and Inspection....................................271
		Installation Overview......................................271
	3.29 FLYWHEEL AND CONNECTING RODS..............................272
		Removal Overview...........................................272
		Inspection.................................................272
		Installation Overview......................................272
	3.30 OIL PAN...................................................273
		Removal....................................................273
		Installation...............................................273
4. FUEL SYSTEM.....................................................275
	4.1 FASTENER TORQUE VALUES.....................................277
		Fastener Torque Values in this Chapter.....................277
	4.2 SPECIFICATIONS: FUEL SYSTEM................................279
		Specifications.............................................279
	4.3 ELECTRONIC FUEL INJECTION (EFI)............................280
		Troubleshooting............................................280
	4.4 IDLE SPEED.................................................281
		General....................................................281
	4.5 AIR CLEANER ASSEMBLY.......................................282
		Removal....................................................282
		Installation...............................................283
		Backplate Assembly: HDI Models.............................283
	4.6 FUEL TANK..................................................285
		General....................................................285
		Removal....................................................285
		Cleaning and Inspection....................................287
		Installation...............................................287
	4.7 THROTTLE POSITION SENSOR (TPS).............................288
		General....................................................288
		Removal....................................................288
		Installation...............................................288
	4.8 INTAKE AIR TEMPERATURE SENSOR (IAT)........................289
		General....................................................289
		Removal....................................................289
		Installation...............................................289
	4.9 ENGINE TEMPERATURE SENSOR (ET).............................290
		General....................................................290
		Removal....................................................290
		Installation...............................................291
	4.10 INDUCTION MODULE..........................................292
		Removal....................................................292
		Installation...............................................293
	4.11 IDLE AIR CONTROL (IAC)....................................294
		General....................................................294
		Removal....................................................294
		Installation...............................................294
	4.12 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)...................295
		General....................................................295
		Removal....................................................295
		Installation...............................................295
	4.13 OXYGEN SENSOR.............................................296
		General....................................................296
		Removal....................................................296
		Installation...............................................296
	4.14 FUEL INJECTORS............................................297
		General....................................................297
		Removal....................................................297
		Installation...............................................297
	4.15 FUEL PUMP.................................................299
		General....................................................299
		Removal....................................................299
		Disassembly/Assembly.......................................301
		Installation...............................................303
	4.16 FUEL PRESSURE TEST........................................307
		General....................................................307
		Testing....................................................307
	4.17 EXHAUST SYSTEM............................................309
		Removal: All but FXDF......................................309
		Disassembly: All but FXDF..................................311
		Assembly: All but FXDF.....................................311
		Installation: All but FXDF.................................311
		Removal: FXDF..............................................312
		Installation: FXDF.........................................313
	4.18 INTAKE LEAK TEST..........................................315
		General....................................................315
		Leak Tester................................................315
		Procedure..................................................315
	4.19 EVAPORATIVE EMISSIONS CONTROL (CA MODELS).................317
		General....................................................317
		Charcoal Canister..........................................317
5. DRIVE...........................................................319
	5.1 FASTENER TORQUE VALUES.....................................321
		Fastener Torque Values in this Chapter.....................321
	5.2 SPECIFICATIONS: DRIVE......................................322
		Specifications.............................................322
	5.3 PRIMARY CHAINCASE COVER....................................323
		General....................................................323
		Removal....................................................323
		Installation...............................................323
	5.4 DRIVE COMPONENTS...........................................324
		Removal....................................................324
		Installation...............................................325
	5.5 PRIMARY CHAINCASE HOUSING..................................329
		Removal....................................................329
		Inspection.................................................329
		Mainshaft Bearing and Lip Seal.............................329
		Mainshaft Bearing Inner Race...............................330
		Shifter Shaft Bushing......................................331
		Installation...............................................332
	5.6 CLUTCH.....................................................334
		Removal and Installation...................................334
		Clutch Pack Only...........................................334
		Clutch Pack and Bearing....................................336
	5.7 TRANSMISSION SPROCKET......................................339
		Removal....................................................339
		Cleaning and Inspection....................................339
		Installation...............................................340
	5.8 DRIVE BELT.................................................342
		Removal....................................................342
		Installation...............................................342
6. TRANSMISSION....................................................345
	6.1 FASTENER TORQUE VALUES.....................................347
		Fastener Torque Values in this Chapter.....................347
	6.2 SPECIFICATIONS: TRANSMISSION...............................348
		Specifications.............................................348
		Service Wear Limits........................................348
	6.3 TRANSMISSION...............................................349
		Power Flow.................................................349
	6.4 SHIFTER LINKAGE............................................351
		Adjustment.................................................351
	6.5 CLUTCH RELEASE COVER.......................................352
		Removal and Disassembly....................................352
		Cleaning and Inspection....................................353
		Assembly and Installation..................................353
	6.6 TRANSMISSION ASSEMBLY......................................354
		Removal....................................................354
		Disassembly................................................355
		Cleaning and Inspection....................................361
		Assembly...................................................361
		Installation...............................................365
	6.7 MAIN DRIVE GEAR AND BEARING................................366
		Removal....................................................366
		Cleaning and Inspection....................................367
		Installation...............................................369
	6.8 TRANSMISSION CASE..........................................373
		Removal....................................................373
		Installation...............................................374
		Disassembly................................................375
		Cleaning and Inspection....................................375
		Assembly...................................................376
7. ELECTRICAL......................................................379
	7.1 FASTENER TORQUE VALUES.....................................381
		Fastener Torque Values in this Chapter.....................381
	7.2 SPECIFICATIONS: ELECTRICAL.................................383
		Specifications.............................................383
	7.3 ELECTRICAL CADDY...........................................384
		Removal....................................................384
		Installation...............................................384
	7.4 ELECTRONIC CONTROL MODULE (ECM)............................386
		General....................................................386
		Replacement................................................386
	7.5 SPARK PLUG CABLES..........................................387
		Removal....................................................387
		Installation...............................................387
	7.6 VOLTAGE REGULATOR..........................................388
		Removal....................................................388
		Installation...............................................388
	7.7 FUSES AND RELAYS...........................................389
		General....................................................389
		Removal and Installation...................................389
	7.8 IGNITION SWITCH/FORK LOCK..................................390
		General....................................................390
		FXD, FXDL, FXDB Models.....................................390
		FXDC, FXDF Models (Ignition Switch Only)...................393
	7.9 BATTERY TRAY AND BATTERY CABLES............................394
		Battery Tray...............................................394
		Battery Cables.............................................395
	7.10 STARTER...................................................396
		General....................................................396
		Removal....................................................396
		Field Coil Assembly........................................396
		Drive Assembly.............................................398
		Installation...............................................399
	7.11 STARTER SOLENOID..........................................400
		Solenoid Assembly..........................................400
		Solenoid Plunger...........................................400
		Solenoid Contacts..........................................400
	7.12 HEADLAMP..................................................403
		General....................................................403
		Bulb Removal...............................................403
		Bulb Installation..........................................405
		Headlamp Assembly Removal..................................405
		Headlamp Assembly Installation.............................405
	7.13 TAIL LAMP.................................................406
		General....................................................406
		Tail Lamp Bulb Replacement: Standard Style.................406
		Base Replacement: All But FXDB.............................406
		Base Replacement: FXDB.....................................408
	7.14 TURN SIGNALS AND RUNNING LIGHTS...........................410
		Bulb Replacement: Bullet Style.............................410
		Front Lamp Housing Replacement.............................410
		Rear Lamp Housing Replacement..............................411
	7.15 STOP-TAIL-TURN (STT) MODULE: FXDB (DOMESTIC ONLY).........414
		General....................................................414
		STT Module Replacement.....................................414
	7.16 TURN SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM)...........415
		Removal....................................................415
		Installation...............................................415
	7.17 CRANK POSITION SENSOR (CKP)...............................417
		General....................................................417
		Removal....................................................417
		Installation...............................................417
	7.18 ALTERNATOR AND STATOR.....................................418
		Removal....................................................418
		Installation...............................................418
	7.19 FUEL GAUGE................................................419
		General....................................................419
		All But FXD Models.........................................419
		FXD Models.................................................419
	7.20 FUEL GAUGE SENDER.........................................423
		Removal....................................................423
		Installation...............................................424
	7.21 INSTRUMENTS: FXDC/FXDF....................................426
		Removal....................................................426
		Installation...............................................426
	7.22 INSTRUMENTS: FXDB/FXDL....................................427
		Removal....................................................427
		Installation...............................................427
	7.23 INSTRUMENTS: FXD..........................................429
		Removal....................................................429
		Installation...............................................429
	7.24 VEHICLE SPEED SENSOR (VSS)................................430
		General....................................................430
		Removal....................................................430
		Installation...............................................430
	7.25 INDICATOR LAMPS...........................................431
		General....................................................431
		Removal....................................................431
		Installation...............................................433
	7.26 NEUTRAL SWITCH............................................434
		General....................................................434
		Removal....................................................434
		Installation...............................................434
	7.27 OIL PRESSURE SWITCH.......................................435
		General....................................................435
		Removal....................................................435
		Installation...............................................435
	7.28 REAR STOPLIGHT SWITCH.....................................436
		General....................................................436
		Removal....................................................436
		Installation...............................................436
	7.29 HORN......................................................437
		Inspection.................................................437
		Replacement................................................437
	7.30 ACTIVE EXHAUST............................................438
		General....................................................438
		Removal....................................................438
		Repair.....................................................438
		Installation...............................................438
	7.31 MAIN WIRING HARNESS.......................................440
		General....................................................440
		Removal....................................................440
		Installation...............................................442
	7.32 HANDLEBAR SWITCH ASSEMBLIES...............................445
		General....................................................445
		Repair Procedures..........................................445
	7.33 RIGHT HANDLEBAR SWITCH....................................446
		Removal....................................................446
		Installation...............................................446
		Disassembly................................................448
		Switch Repair/Replacement..................................449
		Assembly...................................................450
	7.34 LEFT HANDLEBAR SWITCH.....................................452
		Removal....................................................452
		Installation...............................................452
		Disassembly................................................453
		Switch Repair/Replacement..................................453
		Assembly...................................................454
A. APPENDIX A CONNECTOR REPAIR.....................................457
	A.1 AMP MULTILOCK CONNECTORS...................................459
		AMP Multilock Connector Repair.............................459
	A.2 AUTOFUSE ELECTRICAL CONNECTORS.............................463
		Autofuse Connector Repair..................................463
	A.3 DELPHI CONNECTORS..........................................464
		Delphi Connector Repair....................................464
	A.4 DELPHI MAXI FUSE HOUSING...................................466
		Delphi Main Fuse Housing Repair............................466
	A.5 DEUTSCH ELECTRICAL CONNECTORS..............................468
		Deutsch Connector Repair...................................468
	A.6 DEUTSCH STANDARD TERMINAL REPAIR...........................472
		Deutsch Standard Terminal Crimps...........................472
	A.7 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR..................473
		Deutsch Solid Barrel Terminal Crimps.......................473
	A.8 DEUTSCH MINI TERMINAL REPAIR...............................475
		Deutsch Mini Terminal Crimps...............................475
	A.9 MOLEX CONNECTORS...........................................476
		Molex Connector Repair.....................................476
		Crimp Terminal to Lead.....................................477
	A.10 PACKARD 150 METRI-PACK CONNECTORS.........................480
		150 Metri-Pack Connector Repair............................480
	A.11 PACKARD 280 METRI-PACK RELAY AND FUSE BLOCK CONNECTORS....482
		Fuse Block Repair..........................................482
	A.12 PACKARD 480 METRI-PACK CONNECTORS.........................483
		480 Metri-Pack Connector Repair............................483
	A.13 PACKARD 630 METRI-PACK CONNECTORS.........................484
		630 Metri-Pack Connector Repair............................484
	A.14 PACKARD METRI-PACK TERMINALS..............................485
		Metri-Pack Terminal Crimps.................................485
	A.15 PACKARD ECM CONNECTOR.....................................487
		Packard 100W Connector Repair..............................487
	A.16 PACKARD MICRO-64 CONNECTORS...............................489
		Packard Micro-64 Connector Repair..........................489
	A.17 SEALED SPLICE CONNECTORS..................................492
		Sealed Splice Connector Repair.............................492
B. APPENDIX B WIRING...............................................495
	B.1 CONNECTORS.................................................497
		Connector Locations........................................497
	B.2 WIRING DIAGRAMS............................................499
		Wiring Diagram Information.................................499
		2009 Dyna Wiring Diagrams..................................500
C. APPENDIX C CONVERSIONS..........................................545
	C.1 LENGTH CONVERSION..........................................547
		Conversion Table...........................................547
	C.2 FLUID CONVERSION...........................................548
		United States System.......................................548
		Metric System..............................................548
		British Imperial System....................................548
	C.3 TORQUE CONVERSION..........................................549
		United States System.......................................549
		Metric System..............................................549
D. APPENDIX D GLOSSARY.............................................551
	D.1 GLOSSARY...................................................553
		Acronyms and Abbreviations.................................553
TOOLS..............................................................557
TORQUE VALUES......................................................563
INDEX..............................................................571

2009 HARLEY DAVIDSON DYNA MODELS SERVICE MANUAL – PDF DOWNLOAD:

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