2008 Harley Davidson Dyna Service Manual 99481-08 – PDF DOWNLOAD
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2008 Harley Davidson Dyna Service Manual 99481-08 – PDF DOWNLOAD
Language : English
Pages : 555
Downloadable : Yes
File Type : PDF
Size: 36.2 MB
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2008 Harley Davidson Dyna Service Manual 99481-08 – 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 Starter
6 Drive
7 Transmission
8 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Glossary
TABLE OF CONTENTS:
2008 Harley Davidson Dyna Service Manual 99481-08 – PDF DOWNLOAD
1 1 GENERAL
Servicing a New Motorcycle 1-1
Safe Operating Maintenance 1-1
Shop Practices 1-1
Repair Notes 1-1
Safety 1-1
Removing Parts 1-1
Cleaning 1-1
Disassembly and Assembly 1-2
Checking Torques on Fasteners with Lock Patches 1-2
Magnetic Parts Trays 1-2
Repair and Replacement Procedures 1-2
Hardware and Threaded Parts 1-2
Threadlocking Agents 1-2
Wiring, Hoses and Lines 1-2
Instruments and Gauges 1-2
Bearings 1-2
Bushings 1-2
Gaskets 1-2
Lip Type Seals 1-2
O-Rings (Preformed Packings) 1-3
Gears 1-3
Shafts 1-3
Part Replacement 1-3
Exhaust System Leakage 1-3
Cleaning 1-3
Part Protection 1-3
Cleaning Process 1-3
Rust or Corrosion Removal 1-3
Bearings 1-3
Tool Safety 1-3
Air Tools 1-3
Wrenches 1-3
Pliers/Cutters/Pry bars 1-3
Hammers 1-4
Punches/Chisels 1-4
Screwdrivers 1-4
Ratchets and Handles 1-4
Sockets 1-4
Storage Units 1-4
1 2 MAINTENANCE SCHEDULE
General 1-5
1 3 FUEL AND OIL
Fuel 1-8
Gasoline Blends 1-8
Engine Lubrication 1-8
Winter Lubrication 1-9
1 4 ENGINE OIL AND FILTER
Checking and Adding Oil 1-10
Type of Oil 1-10
Checking with Cold Engine 1-10
Checking with Warm Engine 1-10
Changing Oil and Filter 1-11
1 5 BULB REQUIREMENTS
General 1-12
1 6 BRAKES
Fluid Inspection 1-13
Rear Pedal Height 1-13
1 7 AIR CLEANER AND EXHAUST SYSTEM
Removal 1-15
Installation 1-15
Exhaust System Leak Check 1-16
1 8 TIRES AND WHEELS
Tires 1-17
Tire Replacement 1-17
Wheel Bearings 1-18
Wheel Spokes 1-18
1 9 PRIMARY CHAIN
General 1-19
Changing Primary Chaincase Lubricant 1-19
1 10 TRANSMISSION LUBRICANT
Changing Transmission Lubricant 1-21
1 11 CLUTCH
Adjustment 1-22
1 12 REAR BELT AND SPROCKETS
General 1-24
Cleaning 1-24
Inspection 1-24
Sprockets 1-24
Rear Belt 1-24
1 13 REAR BELT DEFLECTION
Inspection 1-26
Adjustment 1-27
1 14 THROTTLE CABLES
Cable Inspection, Lubrication and Adjustment 1-28
Inspection and Lubrication 1-28
Adjustment 1-28
1 15 BLEEDING BRAKES
General 1-29
Procedure 1-29
1 16 BRAKE PADS AND DISCS
Inspection 1-30
Brake Pads 1-30
Brake Disc Thickness 1-30
Brake Disc Lateral Runout and Warpage 1-30
Brake Pad Replacement 1-30
Rear Brake Caliper 1-30
Front Brake Caliper 1-31
1 17 BATTERY MAINTENANCE
General 1-33
Cleaning and Inspection 1-34
Voltmeter Test 1-34
Voltmeter Test 1-34
Charging Battery 1-34
Safety Precautions 1-34
Using a Battery Charger 1-34
Disconnection and Removal 1-35
Storage 1-36
Installation and Connection 1-36
1 18 SUSPENSION ADJUSTMENTS
Rear Shock Preload Adjustment 1-38
III
TABLE OF CONTENTS
1 19 SPARK PLUGS
Inspection 1-39
Spark Plug Cable Inspection 1-39
1 20 STEERING HEAD BEARINGS
Adjustment 1-41
Bearing Adjustment (Fall Away) 1-41
Lubrication 1-41
1 21 FRONT FORK OIL
Replacing Fork Oil 1-42
1 22 CABLE AND CHASSIS LUBRICATION
General 1-43
Cables and Hand Levers 1-43
Jiffy Stand 1-43
1 23 HEADLAMP ALIGNMENT
Inspection 1-44
Adjustment 1-44
All Models 1-44
1 24 CRITICAL FASTENERS
Inspection 1-46
1 25 ENGINE MOUNTS
Inspection 1-47
1 26 STORAGE
General 1-48
Placing in Storage 1-48
Removal from Storage 1-48
1 27 TROUBLESHOOTING
General 1-50
Engine 1-50
Starter Motor Does Not Operate or Does Not Turn Engine
Over 1-50
Engine Turns Over But Does Not Start 1-50
Starts Hard 1-50
Starts But Runs Irregularly or Misses 1-50
Spark Plug Fouls Repeatedly 1-50
Pre-Ignition or Detonation (Knocks or Pings) 1-50
Overheating 1-51
Valve Train Noise 1-51
Excessive Vibration 1-51
Check Engine Light Illuminates During Operation 1-51
Lubrication System 1-51
Oil Does Not Return To Oil Pan 1-51
Engine Uses Too Much Oil Or Smokes Excessively 1-51
Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc 1-51
Low Oil Pressure 1-51
High Oil Pressure 1-51
Electrical System 1-51
Alternator Does Not Charge 1-51
Alternator Charge Rate Is Below Normal 1-51
Speedometer Operates Erratically 1-52
Transmission 1-52
Shifts Hard 1-52
Jumps Out Of Gear 1-52
Clutch Slips 1-52
Clutch Drags Or Does Not Release 1-52
Clutch Chatters 1-52
Handling 1-52
Irregularities 1-52
Brakes 1-52
Brake Does Not Hold Normally 1-52
CHASSIS
2 1 SPECIFICATIONS
Specifications 2-1
Tires 2-1
2 2 VEHICLE IDENTIFICATION NUMBER
(V I N )
General 2-3
2 3 FRONT WHEEL
Removal 2-5
Disassembly 2-5
Cast Wheel 2-5
Cast Wheel, Dual Brakes 2-5
Laced Wheel 2-5
Cleaning and Inspection 2-8
Assembly 2-8
Cast Wheel 2-9
Laced Wheel 2-9
Installation 2-9
2 4 REAR WHEEL
Removal 2-10
Disassembly 2-10
Cleaning and Inspection 2-11
Assembly 2-11
Installation 2-12
2 5 SEALED WHEEL BEARINGS
Inspection 2-13
Removal 2-13
Installation 2-14
2 6 WHEEL LACING: 17 INCH RIM
General 2-16
Procedure 2-16
Hub: Brake Disc Flange Up 2-16
Hub: Sprocket Side Up 2-17
2 7 WHEEL LACING: 19 INCH RIM
Procedure 2-19
2 8 WHEEL LACING: 21 INCH RIM
General 2-23
Procedure 2-23
2 9 TRUING LACED WHEELS
General 2-26
Lateral Truing 2-26
Radial Truing 2-27
IV TABLE OF CONTENTS
TABLE OF CONTENTS
2 10 CHECKING CAST WHEEL RUNOUT
General 2-29
Lateral Runout 2-29
Radial Runout 2-29
2 11 VEHICLE ALIGNMENT
Inspection 2-30
2 12 FRONT BRAKE MASTER CYLINDER
General 2-32
Removal and Disassembly 2-32
Cleaning and Inspection 2-34
Assembly and Installation 2-34
2 13 FRONT BRAKE CALIPER
Removal 2-36
Disassembly 2-36
Cleaning, Inspection and Repair 2-38
Assembly 2-39
Installation 2-39
2 14 REAR BRAKE MASTER CYLINDER
General 2-41
Removal 2-41
Disassembly 2-42
Cleaning and Inspection 2-43
Assembly 2-43
Installation 2-43
2 15 REAR BRAKE CALIPER
Removal 2-45
Disassembly 2-45
Cleaning, Inspection and Repair 2-47
Assembly 2-48
Installation 2-48
2 16 TIRES
General 2-50
Removal 2-50
Cleaning, Inspection and Repair 2-51
Installation 2-51
Tube Type Tires 2-51
Tubeless Tires 2-52
2 17 FRONT FORK
Removal 2-53
Disassembly 2-53
Cleaning and Inspection 2-56
Assembly 2-56
Installation 2-57
2 18 STEERING HEAD
Removal 2-58
Inspection 2-58
Disassembly 2-59
Steering Head Bearing Race Removal 2-59
Assembly 2-60
Installation 2-60
2 19 BELT GUARD
Removal 2-61
Installation 2-61
2 20 DEBRIS DEFLECTOR
Removal 2-62
Installation 2-62
2 21 THROTTLE CONTROL
Removal/Disassembly 2-63
Cleaning and Inspection 2-63
Assembly/Installation 2-63
Throttle Cable Routing 2-63
2 22 REAR SHOCK ABSORBERS
General 2-65
Removal 2-65
Inspection 2-65
Installation 2-65
2 23 REAR FORK
Removal 2-66
Disassembly 2-67
Cleaning and Inspection 2-67
Assembly 2-67
Installation 2-67
2 24 CLUTCH CONTROL
Removal 2-68
Installation 2-68
2 25 HANDLEBARS: ALL BUT FXDWG/FXDF
Removal 2-69
All Models 2-69
FXD/FXDC Models 2-69
FXDB 2-69
FXDL Models 2-70
Installation 2-70
FXD/FXDC Models 2-70
FXDB Models 2-71
FXDL Models 2-71
All Models 2-71
2 26 HANDLEBARS: FXDWG/FXDF
Removal 2-72
Installation 2-72
2 27 FRONT FENDER
Removal 2-75
Installation 2-75
2 28 REAR FENDER
General 2-76
Removal 2-76
Tail Lamp/Turn Signal Harness Routing 2-76
Installation 2-76
FXDWG/FXDF 2-77
Removal 2-77
Installation 2-77
FXD, FXDC, FXDB and FXDL Models 2-77
TABLE OF CONTENTS V
TABLE OF CONTENTS
Removal 2-77
Installation 2-77
2 29 SEAT
Removal 2-78
Installation 2-78
2 30 JIFFY STAND
Cleaning 2-80
Sensor (HDI Models) 2-80
Removal 2-81
Installation 2-81
2 31 ENGINE MOUNTS
Removal 2-83
Front Isolator 2-83
Rear Isolator 2-83
Installation 2-83
Front Isolator 2-83
Rear Isolator 2-83
ENGINE
3 1 SPECIFICATIONS
Specifications 3-1
3 2 SERVICE WEAR LIMITS
General 3-3
3 3 ENGINE OIL FLOW
Oil Feed 3-5
Top End 3-6
Bottom End 3-7
Oil Return 3-9
3 4 OIL PUMP OPERATION
General 3-10
Operation 3-10
3 5 BREATHER OPERATION
General 3-12
3 6 OIL PRESSURE
Oil Pressure Indicator Lamp 3-13
Checking Oil Pressure 3-13
3 7 TROUBLESHOOTING
Diagnosing Valve Train Noise 3-14
Compression Test 3-14
Cylinder Leakdown Test 3-14
Diagnosing Smoking Engine or High Oil Consumption 3-15
Check Prior To Cylinder Head Removal 3-15
Check After Cylinder Head Removal 3-15
3 8 HOW TO USE THIS SECTION
Top End Repair 3-16
Bottom End Repair 3-16
Typical Symptoms 3-16
3 9 TOP END SERVICE
Engine in Chassis 3-17
Engine Removed from Chassis 3-18
3 10 BOTTOM END SERVICE
Engine in Chassis 3-19
Engine Removed From Chassis 3-20
3 11 STRIPPING MOTORCYCLE FOR
SERVICE
Procedure 3-21
3 12 ASSEMBLING MOTORCYCLE AFTER
SERVICE
Procedure 3-22
3 13 REMOVING ENGINE FROM CHASSIS
Procedure 3-23
3 14 INSTALLING ENGINE IN CHASSIS
Procedure 3-24
3 15 TOP END OVERHAUL: DISASSEMBLY
General 3-26
Breather Assembly 3-26
Rocker Arm Support Plate 3-27
Push Rods, Lifters and Covers 3-28
Cylinder Head 3-29
Cylinder 3-30
Piston 3-30
3 16 TOP END OVERHAUL: ASSEMBLY
General 3-32
Piston 3-32
Cylinder 3-33
Cylinder Head 3-35
Push Rods, Lifters and Covers 3-39
Rocker Arm Support Plate 3-40
Breather Assembly 3-41
3 17 BOTTOM END OVERHAUL:
DISASSEMBLY
General 3-43
Cover and Cam Support Plate 3-43
Prepare Engine 3-43
Cam Chain and Sprockets 3-43
Cam Support Plate 3-44
Crankcase 3-45
3 18 BOTTOM END OVERHAUL: ASSEMBLY
General 3-47
Crankcase 3-47
Cover and Cam Support Plate 3-49
3 19 BREATHER ASSEMBLY
Removal Overview 3-54
Disassembly 3-54
Cleaning and Inspection 3-54
Assembly 3-54
VI TABLE OF CONTENTS
TABLE OF CONTENTS
Installation Overview 3-54
3 20 ROCKER ARM SUPPORT PLATE
Removal Overview 3-55
Disassembly 3-55
Cleaning and Inspection 3-55
Inspection 3-55
Rocker Shaft Fit 3-55
Rocker Arm Shaft to Bushing 3-56
Replace Rocker Arm Bushings 3-56
Assembly 3-57
Installation Overview 3-57
3 21 PUSH RODS, LIFTERS AND COVERS
Removal Overview 3-58
Disassembly 3-58
Cleaning and Inspection 3-58
Lifter Inspection 3-59
Assembly 3-59
Installation Overview 3-60
3 22 CYLINDER HEAD
Removal Overview 3-61
Disassembly 3-61
Cleaning 3-62
Inspection 3-63
Cylinder Head 3-63
Valve Guides 3-63
Valves 3-63
Valve Springs 3-63
Tapered Keepers 3-64
Valve Seats 3-64
Valve Guide Replacement 3-64
Removal 3-64
Installation 3-65
Valve and Seat Refacing 3-68
Assembly 3-70
Installation Overview 3-71
3 23 CYLINDER
Removal Overview 3-72
Cleaning 3-72
Inspection 3-73
Deglazing Cylinder 3-74
Boring and Honing Cylinder 3-75
Installation Overview 3-75
3 24 PISTON
Removal Overview 3-76
Disassembly 3-76
Piston Rings 3-76
Cleaning 3-76
Inspection 3-77
Assembly 3-78
Checking Piston Ring Gap 3-78
Installing Piston Rings 3-79
Installation Overview 3-80
3 25 COVER AND CAM SUPPORT PLATE
Removal Overview 3-81
Camshafts 3-82
Removal 3-82
Assembly 3-83
Oil Pressure Relief Valve 3-84
Removal 3-84
Installation 3-84
Inspection 3-85
Cam Needle Bearings 3-85
Removal 3-85
Installation 3-86
Cleaning and Inspection 3-88
Oil Pressure Valve 3-88
Cam Support Plate 3-88
Installation Overview 3-88
3 26 OIL PUMP
Removal Overview 3-89
Cleaning and Inspection 3-89
Installation Overview 3-89
3 27 CRANKCASE
Removal Overview 3-90
Right Crankcase Half 3-90
Crankshaft Bearing Removal 3-90
Crankshaft Bearing Installation 3-90
Piston Jets Removal 3-91
Piston Jets Installation 3-91
Left Crankcase Half 3-91
Crankshaft (Roller) Bearing Removal 3-91
Crankshaft (Roller) Bearing Installation 3-93
Sprocket Shaft Bearing Inner Race 3-94
Removal 3-94
Installation 3-95
Cylinder Studs 3-96
Removal 3-96
Installation 3-96
Pipe Plug and Oil Fittings 3-97
Removal 3-97
Installation 3-97
Cleaning and Inspection 3-97
Installation Overview 3-97
3 28 FLYWHEEL AND CONNECTING RODS
Removal Overview 3-98
Inspection 3-98
Installation Overview 3-98
3 29 OIL PAN
Removal 3-99
Installation 3-99
FUEL SYSTEM
4 1 SPECIFICATIONS: FUEL SYSTEM
Specifications 4-1
4 2 ELECTRONIC FUEL INJECTION (EFI)
Troubleshooting 4-2
4 3 IDLE SPEED
General 4-3
TABLE OF CONTENTS VII
TABLE OF CONTENTS
4 4 AIR CLEANER ASSEMBLY
Removal 4-4
Installation 4-5
Backplate Assembly: HDI Models 4-5
4 5 FUEL TANK
General 4-7
Removal 4-7
Cleaning and Inspection 4-9
Installation 4-9
Vapor Valve 4-9
4 6 THROTTLE POSITION SENSOR (TPS)
General 4-10
Removal 4-10
Installation 4-10
4 7 INTAKE AIR TEMPERATURE SENSOR
(IAT)
General 4-11
Removal 4-11
Installation 4-11
4 8 ENGINE TEMPERATURE SENSOR (ET)
General 4-12
Removal 4-12
Installation 4-13
4 9 INDUCTION MODULE
Removal 4-14
Installation 4-15
4 10 IDLE AIR CONTROL (IAC)
General 4-16
Removal 4-16
Installation 4-16
4 11 MANIFOLD ABSOLUTE PRESSURE
SENSOR (MAP)
General 4-17
Removal 4-17
Installation 4-17
4 12 OXYGEN SENSOR
General 4-18
Removal 4-18
Installation 4-18
4 13 FUEL INJECTORS
General 4-19
Removal 4-19
Installation 4-19
4 14 FUEL PUMP
General 4-21
Removal 4-21
Disassembly/Assembly 4-23
Fuel Filter 4-23
Regulator 4-23
Inlet Sock 4-24
Fuel Pump 4-25
Installation 4-25
4 15 FUEL PRESSURE TEST
General 4-29
Testing 4-29
4 16 EXHAUST SYSTEM
Removal: All but FXDF 4-31
Disassembly: All but FXDF 4-33
Assembly: All but FXDF 4-33
Installation: All but FXDF 4-33
Removal: FXDF 4-34
Installation: FXDF 4-35
4 17 INTAKE LEAK TEST
General 4-37
Leak Tester 4-37
Parts List 4-37
Tester Assembly 4-37
Tester Adjustment 4-37
Procedure 4-37
4 18 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS)
General 4-39
Charcoal Canister 4-39
Removal 4-39
Installation 4-40
STARTER
5 1 SPECIFICATIONS: STARTER
Specifications 5-1
5 2 STARTER
General 5-2
Starter Relay 5-2
Wiring Diagrams 5-2
Removal 5-2
Installation 5-2
Testing 5-2
Armature 5-2
Brushes and Brush Holder 5-5
Field Coil Assembly 5-6
Disassembly 5-6
Inspection 5-6
Assembly 5-6
Drive Assembly 5-7
Disassembly 5-7
Inspection 5-7
Assembly 5-7
5 3 STARTER SOLENOID
Solenoid Assembly 5-8
Disassembly 5-8
Assembly 5-8
Solenoid Plunger 5-8
Disassembly 5-8
VIII TABLE OF CONTENTS
TABLE OF CONTENTS
Assembly 5-8
Solenoid Contacts 5-8
Disassembly 5-8
Assembly 5-9
DRIVE
6 1 SPECIFICATIONS: DRIVE
Specifications 6-1
6 2 PRIMARY CHAINCASE COVER
General 6-2
Removal 6-2
Installation 6-2
6 3 DRIVE COMPONENTS
Removal 6-3
Installation 6-4
6 4 PRIMARY CHAINCASE HOUSING
Removal 6-8
Inspection 6-8
Mainshaft Bearing and Lip Seal 6-8
Removal 6-8
Installation 6-8
Mainshaft Bearing Inner Race 6-9
Removal 6-9
Installation 6-9
Shifter Shaft Bushing 6-10
Installation 6-11
6 5 CLUTCH
Removal and Installation 6-13
Clutch Pack Only 6-13
Partial Disassembly 6-13
Cleaning And Inspection 6-13
Assembly 6-14
Clutch Pack and Bearing 6-15
Complete Disassembly 6-15
Assembly 6-16
6 6 TRANSMISSION SPROCKET
Removal 6-18
Cleaning and Inspection 6-18
Installation 6-19
6 7 DRIVE BELT
Removal 6-21
Installation 6-21
TRANSMISSION
7 1 SPECIFICATIONS:TRANSMISSION
Specifications 7-1
Service Wear Limits 7-1
7 2 TRANSMISSION
Power Flow 7-2
Neutral 7-2
1st Gear 7-2
2nd Gear 7-2
3rd Gear 7-2
4th Gear 7-2
5th Gear 7-2
6th Gear 7-2
7 3 SHIFTER LINKAGE
Adjustment 7-4
7 4 CLUTCH RELEASE COVER
Removal and Disassembly 7-5
Cleaning and Inspection 7-5
Assembly and Installation 7-6
7 5 TRANSMISSION ASSEMBLY
Removal 7-7
Disassembly 7-8
Shifter Cam/Shifter Forks 7-8
Mainshaft 7-9
Countershaft 7-13
Replacing Side Door Bearings 7-15
Cleaning and Inspection 7-15
Assembly 7-15
Installing Side Door Bearings 7-15
Countershaft 7-16
Mainshaft 7-16
Shifter Cam/Shifter Forks 7-17
Installation 7-18
7 6 MAIN DRIVE GEAR AND BEARING
Removal 7-19
Cleaning and Inspection 7-20
Needle Bearing Replacement 7-20
Installation 7-22
Installing Main Drive Gear Bearing 7-23
Installing Main Drive Gear 7-23
Installing Main Drive Gear Seal 7-24
7 7 TRANSMISSION CASE
Removal 7-26
Installation 7-27
Disassembly 7-28
Shifter Arm Assembly 7-28
Cleaning and Inspection 7-28
Assembly 7-29
Countershaft Needle Bearing Replacement 7-29
Shifter Pawl Lever Assembly 7-29
ELECTRICAL
8 1 SPECIFICATIONS: ELECTRICAL
Specifications 8-1
8 2 ELECTRICAL CADDY
Removal 8-2
Installation 8-2
8 3 ELECTRONIC CONTROL MODULE (ECM)
General 8-4
Replacement 8-4
TABLE OF CONTENTS IX
TABLE OF CONTENTS
8 4 SPARK PLUG CABLES
Removal 8-5
Installation 8-5
8 5 VOLTAGE REGULATOR
Removal 8-6
Installation 8-6
8 6 FUSES AND RELAYS
General 8-7
Removal and Installation 8-7
Relays 8-7
Fuses 8-7
8 7 IGNITION SWITCH/FORK LOCK
General 8-8
FXD, FXDL, FXDB 8-8
Removal 8-8
Installation 8-9
FXDWG, FXDC, FXDF Models (Ignition Switch Only) 8-11
8 8 BATTERY TRAY AND BATTERY CABLES
Battery Tray 8-12
Removal 8-12
Installation 8-12
Battery Cables 8-13
Routing 8-13
8 9 HEADLAMP
General 8-14
Bulb Removal 8-14
Single Bulb Headlamp 8-14
Dual Bulb Headlamp 8-15
Bulb Installation 8-16
Headlamp Assembly Removal 8-16
Headlamp Assembly Installation 8-16
8 10 TAIL LAMP
General 8-17
Tail Lamp Bulb Replacement: Standard Style 8-17
Base Replacement 8-17
8 11 TURN SIGNALS AND RUNNING LIGHTS
Bulb Replacement: Bullet Style 8-19
Front Lamp Housing Replacement 8-19
Rear Lamp Housing Replacement 8-20
8 12 TURN SIGNAL AND SECURITY
MODULE (TSM/TSSM/HFSM)
Removal 8-23
Installation 8-23
8 13 CRANK POSITION SENSOR (CKP)
General 8-25
Removal 8-25
Installation 8-25
8 14 ALTERNATOR AND STATOR
Removal/Disassembly 8-26
Assembly/Installation 8-26
8 15 FUEL GAUGE
General 8-27
All But FXD Models 8-27
Removal 8-27
Installation 8-27
FXD Models 8-27
Console Removal 8-27
Gauge Removal 8-29
Gauge Installation 8-29
Console Installation 8-29
8 16 FUEL GAUGE SENDER
Removal 8-31
Installation 8-32
8 17 INSTRUMENTS: FXDWG/FXDC/FXDF
Removal 8-34
Speedometer 8-34
Installation 8-34
Speedometer 8-34
8 18 INSTRUMENTS: FXDL/FXDB
Removal 8-35
General 8-35
Speedometer 8-35
Tachometer 8-35
Installation 8-35
General 8-35
Speedometer 8-35
Tachometer 8-35
8 19 INSTRUMENTS: FXD
Removal 8-37
Installation 8-37
8 20 VEHICLE SPEED SENSOR (VSS)
General 8-38
Removal 8-38
Installation 8-38
8 21 INDICATOR LAMPS
General 8-39
Removal 8-39
FXDWG/FXDC/FXDF Models 8-39
FXDB Models 8-39
FXD Models 8-40
FXDL Models 8-40
Installation 8-40
FXDWG/ FXDC/FXDF Models 8-40
FXDB Models 8-41
FXD Models 8-41
FXDL Models 8-41
8 22 NEUTRAL SWITCH
General 8-42
Removal 8-42
Installation 8-42
8 23 OIL PRESSURE SWITCH
General 8-43
X TABLE OF CONTENTS
TABLE OF CONTENTS
Removal 8-43
Installation 8-43
8 24 REAR STOPLIGHT SWITCH
General 8-44
Removal 8-44
Installation 8-44
8 25 HORN
Inspection 8-45
Replacement 8-45
8 26 ACTIVE EXHAUST
General 8-46
Removal 8-46
Repair 8-46
Installation 8-46
8 27 MAIN WIRING HARNESS
General 8-48
Removal 8-48
Installation 8-50
8 28 HANDLEBAR SWITCH ASSEMBLIES
General 8-53
Repair Procedures 8-53
8 29 RIGHT HANDLEBAR SWITCH
Removal 8-54
Installation 8-54
Disassembly 8-56
Switch Repair/Replacement 8-57
Upper Housing Repair 8-57
Lower Housing Repair 8-57
Turn-Right Signal Switch 8-58
Front Stoplight Switch 8-58
Assembly 8-58
8 30 LEFT HANDLEBAR SWITCH
Removal 8-60
Installation 8-60
Disassembly 8-61
Switch Repair/Replacement 8-61
Upper Housing Repair 8-61
Lower Housing Repair 8-62
Turn-Left Signal Switch 8-62
Clutch Interlock Switch 8-62
Assembly 8-62
APPENDIX A CONNECTOR REPAIR
A 1 AMP 1-PLACE CONNECTORS
AMP 1-Place Connector Repair A-1
General A-1
Separating Pin and Socket Housings A-1
Mating Pin and Socket Housings A-1
Removing Socket Terminals A-1
Installing Socket Terminal A-1
Removing Pin Terminal A-1
Installing Pin Terminal A-2
A 2 AMP MULTILOCK CONNECTORS
AMP Multilock Connector Repair A-3
General A-3
Separating Pin and Socket Housings A-3
Mating Pin and Socket Housings A-3
Removing Terminals from Housing A-3
Inserting Terminals into Housing A-4
Preparing Wire Leads for Crimping A-4
Crimping Terminals to Leads A-5
Inspecting Crimped Terminals A-6
A 3 AUTOFUSE ELECTRICAL
CONNECTORS
Autofuse Connector Repair A-7
General A-7
Disassembly A-7
Assembly A-7
A 4 DELPHI CONNECTORS
Delphi Connector Repair A-8
General A-8
Separating Pin and Socket Housings A-8
Mating Pin and Socket Housings A-8
Removing Socket Terminals A-8
Installing Socket Terminals A-8
A 5 DELPHI MAXI FUSE HOUSING
Delphi Maxi-Fuse Housing Repair A-10
General A-10
Removing Maxi-Fuse A-10
Installing Maxi-Fuse A-10
Removing Socket Terminals A-10
Installing Socket Terminals A-10
A 6 DEUTSCH ELECTRICAL CONNECTORS
Deutsch Connector Repair A-12
General A-12
Separating Pin and Socket Housings A-12
Mating Pin and Socket Housings A-12
Removing Socket Terminals A-12
Installing Socket Terminals A-12
Removing Pin Terminals A-14
Installing Pin Terminals A-14
Crimping Terminals A-15
A 7 DEUTSCH STANDARD TERMINAL
REPAIR
Deutsch Standard Terminal Crimps A-16
Preparing Wire Leads for Crimping A-16
Crimping Terminal to Lead A-16
Inspecting Crimps A-16
A 8 DEUTSCH SOLID BARREL MINI
TERMINAL REPAIR
Deutsch Solid Barrel Terminal Crimps A-17
Preparing Wire Leads For Crimping A-17
Adjusting Crimper Tool A-17
Crimping a Barrel Contact To Wire Lead A-17
Inspecting Crimps A-17
TABLE OF CONTENTS XI
TABLE OF CONTENTS
A 9 DEUTSCH MINI TERMINAL REPAIR
Deutsch Mini Terminal Crimps A-19
Preparing Wire Leads for Crimping A-19
Crimping a Mini Terminal to Wire Lead A-19
Inspecting Crimps A-19
A 10 MOLEX CONNECTORS
Molex Connector Repair A-20
Separating Pin and Socket Housings A-20
Mating Pin and Socket Housings A-20
Removing Terminals A-20
Installing Terminals A-20
Crimp Terminal to Lead A-21
Prepare Lead A-21
Prepare Tool A-21
Position Terminal in the Punch/Die A-22
Insert Stripped Lead A-22
Crimp Terminal to Lead A-22
Inspect Crimp A-23
A 11 PACKARD 150 METRI-PACK
CONNECTORS
150 Metri-Pack Connector Repair A-24
General A-24
Separating Pin and Socket Housings A-24
Mating Pin and Socket Housings A-24
Removing Socket Terminal A-24
Inserting Socket Terminal A-24
A 12 PACKARD 280 METRI-PACK RELAY
AND FUSE BLOCK CONNECTORS
Fuse Block Repair A-26
Removing Socket Terminals A-26
Installing Socket Terminals A-26
Crimping Terminals A-26
A 13 PACKARD 480 METRI-PACK
CONNECTORS
480 Metri-Pack Connector Repair A-27
General A-27
Separating Pin and Socket Housings A-27
Mating Pin and Socket Housings A-27
Removing Socket Terminals A-27
Installing Socket Terminals A-27
A 14 PACKARD 630 METRI-PACK
CONNECTORS
630 Metri-Pack Connector Repair A-28
General A-28
Separating Pin and Socket Housings A-28
Mating Pin and Socket Housings A-28
Removing Socket Terminal A-28
Installing Socket Terminal A-28
A 15 PACKARD METRI-PACK TERMINALS
Metri-Pack Terminal Crimps A-29
Matching Terminal To Crimper A-29
Preparing Wire Lead A-29
Crimping Wire Core A-29
Crimping Insulation/Seal A-29
Inspecting Crimps A-30
A 16 PACKARD ECM CONNECTOR
Packard 100W Connector Repair A-31
General A-31
Separating Socket Housing From ECM A-31
Mating Socket Housing To ECM A-31
Removing Socket Terminal A-31
Installing Socket Terminal A-31
Crimping Terminals A-31
A 17 PACKARD MICRO-64 CONNECTORS
Packard Micro-64 Connector Repair A-33
General A-33
Separating Pin and Socket Housings A-33
Mating Pin and Socket Housings A-33
Removing Terminal A-33
Installing Terminal A-33
Preparing Wire Leads for Crimping A-34
Crimping Terminals A-34
Inspecting Crimps A-34
A 18 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair A-36
General A-36
Preparing Wire Leads A-36
Splicing Wire Leads A-36
Inspecting Seals A-36
APPENDIX B WIRING
B 1 CONNECTORS
Connector Locations B-1
Function/Location B-1
Place and Color B-1
Connector Number B-1
Repair Instructions B-1
B 2 WIRING DIAGRAMS
Wiring Diagram Information B-3
Wire Color Codes B-3
Wiring Diagram Symbols B-3
2008 Dyna Wiring Diagrams B-4
APPENDIX C CONVERSIONS
C 1 LENGTH CONVERSION
Conversion Table C-1
C 2 FLUID CONVERSION
United States System C-2
Metric System C-2
British Imperial System C-2
C 3 TORQUE CONVERSION
United States System C-3
Metric System C-3
XII TABLE OF CONTENTS
TABLE OF CONTENTS
APPENDIX D GLOSSARY
D 1 GLOSSARY
Acronyms and Abbreviations D-1
REFERENCE MATERIAL
TOOLS I
TORQUE VALUES VII
INDEX XV
TABLE
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V