2017 Harley Davidson Dyna Models Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2017 Harley Davidson Dyna Models Service Manual – PDF DOWNLOAD
GENERAL:
This service manual has been prepared with the following purposes in mind:
- То acquaint the user with the construction of the HarleyDavidson product and assist in the performance of basic maintenance and repair.
- То introduce the professional Harley-Davidson technician to 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 profitaЫe.
HOW ТО USE YOUR MANUAL:
Refer to the tаЫе 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
А Appendix А Wiring
в Appendix В Reference
- 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:
2017 Harley Davidson Dyna Models Service Manual – PDF DOWNLOAD
1 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 1-1
1 2 GENERAL
Servicing а New Motorcycle 1-3
Safe Operating Maintenance 1-3
Disposal and Recycling 1-3
Shop Practices 1-3
Repair Notes 1-3
Safety 1-3
Removing Parts 1-3
Cleaning 1-3
Cleaning Fastener T hreads 1-4
DisassemЫy and AssemЫy 1-4
Checking Torques оп Fasteners 1-4
Magnetic Parts Тгауs 1-4
Repair and Replacement Procedures 1-4
Hardware and Threaded Parts 1-4
T hreadlocking Agents 1-4
Wiring, Hoses and Lines 1-4
lnstruments and Gauges 1-4
Bearings 1-4
Bushings 1-4
Gaskets 1-4
Lip-Туре Seals 1-5
O-Rings 1-5
Gears 1-5
Shafts 1-5
Part Replacement 1-5
Cleaning 1-5
Protecting Rubber Parts 1-5
Cleaning Process 1-5
Rust ог Corrosion Removal 1-5
Bearings 1-5
Tool Safety 1-5
Air Tools 1-5
Wrenches 1-6
Pliers/Cutters/Pry Вагs 1-6
Hammers 1-6
Punches/Chisels 1-6
Screwdrivers 1-6
Ratchets and Handles 1-6
Sockets 1-6
Storage Units 1-6
1 3 FUEL AND OIL
Fuel 1-7
Gasoline Blends 1-7
Engine Lubrication 1-7
Low Temperature Lubrication 1-8
1 4 MAINTENANCE SCHEDULE
General 1-9
1 5 ENGINE OIL AND FILTER
Check Engine Oil Level 1-14
Oil Level Cold Check 1-14
Oil Level Hot Check 1-14
Changing Oil and Oil Filter 1-14
1 6 AIR CLEANER AND EXHAUST SYSTEM
Removal, AII But НО103 and 110 1-16
lnstallation, AII But НО103 and 110 1-17
кemovaI, нu·Iu,j ,- , ,
lnstallation, НО103 1-18
Removal: FXDLS 1-18
Cleaning: FXDLS 1-18
lnstallation: FXDLS 1-19
Check Exhaust System Leakage 1-19
Exhaust System Leakage 1-19
1 7 TIRES AND WHEELS
Tires 1-20
Тiге Replacement 1-20
Dunlop 1-21
Michelin 1-21
Wheel Bearings 1-22
Wheel Spokes 1-22
ldentify Wheel Spoke Groups 1-22
Adjust Wheel Spokes 1-22
1 8 PRIMARY CHAINCASE LUBRICANT
Change Primary Chaincase Lubricant 1-24
1 9 TRANSMISSION LUBRICANT
Check Transmission Lubricant 1-26
Change Transmission Lubricant 1-26
1 1 О CLUTCH CABLE
Adjustment 1-28 U)
1 11 DRIVE BELT AND SPROCKETS
General 1-30
Cleaning 1-30
lnspection 1-30
Sprockets 1-30
Drive Belt 1-30
Check Drive Belt Deflection 1-31 LL
Adjusting Belt Deflection 1-32 О
1 12 ТНRОТТLЕ CABLES
СаЫе lnspection and Lubrication 1-34
СаЫе Adjustment 1-34
Operation 1-34
Adjustment 1-34
1 13 CABLE AND CHASSIS LUBRICATION
General 1-36
СаЫеs and Hand Levers 1-36
Jiffy Stand 1-36
1 14 BRAKES
Fluid lnspection 1-37
Rear Pedal Height 1-37
lnspect Brake Lines 1-37
1 15 BRAKE PADS AND DISCS
lnspection 1-39
Brake Pads 1-39
Brake Disc 1-39
Brake Pad Replacement 1-40
Rear Brake Caliper 1-40
Front Вгаkе Caliper 1 -40
1 16 SPARK PLUGS
lnspection 1-42
1 17 STEERING HEAD BEARINGS
Adjustment 1-43
Bearing Adjustment (Measurement) 1-43
Bearing Adjustment (Fall-Away) 1-43
Lubrication 1-44
1 18 BATTERY MAINTENANCE
General 1-45
Cleaning and lnspection 1 -46
Voltage Test 1-46
Charging Battery 1-46
Safety Precautions 1-46
Using а Battery Charger 1-46
Battery Tender Connector 1-47
Disconnection and Removal 1-4 7
Storage 1-48
lnstallation and Connection 1-48
1 19 ENGINE MOUNTS
lnspection 1-50
1 20 HEADLAMP ALIGNMENT
Headlamp Alignment 1-51
Headlamp Adjustment: AII but FXDL 1-51
Headlamp Adjustment: FXDL 1-52
1 21 SUSPENSION ADJUSTMENTS: ALL
BUT FXDLS
Shock Absorber Preload: AII except FXDLS 1-53
1 22 SUSPENSION ADJUSTMENTS: FXDLS
Shock Absorber Preload Adjustment 1-54
1 23 STORAGE
General 1-55
Placing in Storage 1-55
Removal from Storage 1-55
1 24 TROUBLESHOOTING
General 1-56
Engine 1-56
Starter Motor Does Not Operate ог Does Not Turn Engine
Over 1-56
Engine Turns Over But Does Not Start 1-56
Starts Hard 1-56
Starts But Runs lrregularly ог Misses 1-56
Spark Plug Fouls Repeatedly 1-56
Pre-lgnition ог Detonation (Knocks ог Pings ) 1-56
Overheating 1-57
Valve Train Noise 1-57
Excessive Vibration 1-57
Check Engine Light llluminates During Operation 1-57
Lubrication System 1-57
Oil Does Not Return То Oil Рап 1-57
Engine Uses Тоо Much Oil Ог Smokes Excessively 1-57
Engine Leaks Oil From Cases, Pushrods, Hoses,
Etc 1-57
Low Oil Pressure 1-57
High Oil Pressure 1-57
Electrical System 1-57
VI TABLE OF CONTENTS
Alternator Does Not Charge 1-57
Alternator Charge Rate Is Below Normal 1-57
Speedometer Operates Erratically 1-58
Transmission 1-58
Shifts Hard 1-58
Jumps Out Of Gear 1-58
Clutch Slips: Mechanical 1-58
Clutch Slips: Hydraulic 1-58
Clutch Drags Ог Does Not Release 1-58
Clutch Chatters 1-58
Handling 1-58
lrregularities 1-58
Brakes 1-58
Brake Does Not Hold Normally 1-58
CHASSIS
2 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 2-1
2 2 SPECIFICATIONS
Specifications 2-5
Chassis Specifications 2-5
Tire Specifications 2-6
2 3 VEHICLE IDENTIFICATION NUMBER
(VIN)
Vehicle ldentification Number 2-8
2 4 FRONT WHEEL
Removal 2-10
DisassemЫy 2-1 О
Cast Wheel 2-10
Cast Wheel, Dual Brakes 2-10
Laced Wheel 2-10
Cleaning and lnspection 2-13
AssemЬly 2-13
Cast Wheel 2-13
Laced Wheel 2-14
lnstallation 2-14
2 5 REAR WHEEL
Removal 2-16
DisassemЫy 2-16
Cleaning and lnspection 2-17
AssemЬly 2-18
lnstallation 2-18
2 6 SEALED WHEEL BEARINGS
lnspect 2-20
Removal 2-20
lnstallation 2-22
2 7 WHEEL LACING
Wheel Lacing: Angle Flange Hub 2-24
Wheel Lacing: Straight Flange Hub, Single Hole Circle 2-25
Wheel Lacing: Straight Flange Hub, Dual Hole Circle 2-27
2 8 CHECKING AND TRUING WHEELS
General 2-29
Checking Wheel Runout 2-29
Checking Radial Runout 2-29
Checking Lateral Runout 2-29
Laced Wheel Rim Offset 2-30
True Laced Wheels 2-33
Adjust Radial Runout 2-33
Adjust Lateral Runout 2-33
2 9 VEHICLE ALIGNMENT
lnspection 2-35
2 1 О FRONT BRAKE MASTER CYLINDER
General 2-37
Removal and DisassemЬ/y 2-37
Cleaning and lnspection 2-39
AssemЬ/y and lnstallation 2-39
2 11 FRONT BRAKE CALIPER
Removal 2-41
DisassemЬ/y 2-41
Cleaning, lnspection and Repair 2-43
AssemЬ/y 2-44
lnstallation 2-45
2 12 REAR BRAKE MASTER CYLINDER
Removal 2-4 7
DisassemЬ/y 2-49
Cleaning and lnspection 2-49
AssemЬ/y 2-50
lnstallation 2-50
2 13 REAR BRAKE CALIPER
Removal 2-52
DisassemЬ/y 2-52
C/eaning, lnspection and Repair 2-54
AssemЬ/y 2-54
lnstallation 2-55
2 14 BRAKE LINES
Front Master Cylinder to Front Caliper Line AssemЬ/y 2-56
Removal 2-56
1 nstal/ation 2-56
ABS Module to Front Manifold Brake Lines 2-56
Removal 2-56
1 nstallation 2-58
Rear Master Cylinder to ABS Module 2-59
Removal 2-59
lnstallation 2-59
ABS Module to Rear Brake Caliper 2-61
Removal 2-61
lnstallation 2-61
2 15 ABS MODULE (EHCU)
General 2-63
Electro Hydraulic Control Unit (EHCU) 2-63
Removal 2-63
lnstallation 2-65
2 16 BLEEDING BRAKES
Genera/ 2-66
Procedure 2-66
TABLE OF CONTENTS
2 17 TIRES
General 2-68
Remove 2-68
Clean, lnspect and Repair 2-68
lnstallation 2-69
Tube Туре Tires 2-69
Tubeless Tires 2-69
Check Тiге Runout 2-70
Lateral Runout 2-70
Radial Runout 2-70
Balance Wheel 2-70
Static vs Dynamic 2-70
Weights 2-71
2 18 FRONT FORK
Check For Oil Leak 2-72
Fork Oil Seals 2-72
Check Oil Leak 2-72
Removal 2-72
DisassemЬ/y: AII But FXDLS Left Side 2-72
DisassemЬ/y: Cartridge Fork (FXDLS Left Side) 2-75
Cleaning and lnspection 2-77
AssemЬ/y: AII But FXDLS Left Side 2-78
AssemЬ/y: Cartridge Fork (FXDLS Left Side) 2-79
lnstallation 2-82
2 19 STEERING HEAD
Removal 2-83
lnspection 2-83
DisassemЬ/y 2-84
Steering Head Bearing Race Removal 2-84
AssemЬ/y 2-84
lnstallation 2-84
2 20 BELT GUARD AND DEBRIS
DEFLECTOR
Belt Guard Removal 2-85
Belt Guard lnstallation 2-85
Debris Deflector Removal 2-85
Debris Deflector lnstallation 2-85
2 21 CABLE THROTTLE CONTROL
Removal/DisassemЬ/y 2-87
Cleaning and lnspection 2-87
AssemЬ/y/lnstallation 2-87
Thrott/e СаЬ/е Routing 2-88
2 22 SHOCK ABSORBERS
Removal 2-89
lnspection 2-89
lnstallation 2-90
2 23 REAR FORK
Removal 2-91
DisassemЬ/y 2-91
Cleaning and lnspection 2-92
AssemЬ/y 2-92
lnstallation 2-92
TABLE OF CONTENTS VII
TABLE OF CONTENTS
2 24 CABLE CLUTCH CONTROL
Removal 2-93
lnstallation 2-93
2 25 HANDLEBAR: FXDB, FXDF, FXDLS
AND FXDWG
Removal 2-94
Remove Handlebar 2-94
Remove Risers 2-94
lnstallation 2-94
Handlebar Risers 2-94
Handlebar 2-95
2 26 HANDLEBAR: FXDL
Removal 2-97
lnstallation 2-97
Handlebar and Riser Adjustment 2-99
2 27 SPEED SCREEN: FXDLS
Remove 2-100
lnstall 2-100
2 28 FRONT FENDER
Removal 2-1 О 1
lnstallation 2-101
2 29 REAR FENDER
General 2-102
Removal 2-102
Tail LampfТurn Signal Harness Routing 2-102
lnstallation 2-102
FXDL 2-104
Removal 2-104
lnstallation 2-104
FXDB, FXDLS 2-104
Removal 2-104
lnstallation 2-104
FXDWG 2-105
Removal 2-105
Sissy Bar 2-106
lnstallation 2-106
FXDF 2-106
Removal 2-106
lnstallation 2-107
2 30 SEAT
Removal 2-108
Seat and Seat Strap: AII But FXDWG 2-108
Seat and Seat Strap: FXDWG 2-108
lnstallation 2-109
Seat and Seat Strap: AII But FXDWG 2-109
Seat and Seat Strap: FXDWG 2-109
Lumbar Pad: FXDL 2-110
Removal 2-110
lnstallation 2-110
2 31 FOOTBOARDS AND FOOTRESTS
Rider Footboards 2-111
Removal 2-111
DisassemЫy 2-111
VIII TABLE OF CONTENTS
AssemЫy 2-111
lnstallation 2-111
Rider Footrests: Mid Controls 2-112
Removal 2-112
lnstallation 2-112
Rider Footrests: Forward Controls 2 -113
Removal 2-113
lnstallation 2-113
Passenger Footrests: AII But FXDB 2-113
Removal 2-113
lnstallation 2-113
2 32 JIFFY STAND
Cleaning 2-115
Jiffy Stand Sensor: HDI Models 2-117
Removal 2-117
lnstallation 2-117
2 33 FORK LOCK
Removal 2-119
lnstallation 2-119
2 34 ENGINE MOUNTS
Removal 2-121
Front lsolator 2-121
Rear lsolator 2-121
lnstallation 2-121
Front lsolator 2-121
Rear lsolator 2-121
2 35 SAREE GUARD: INDIA MODELS
Replacement 2-123
Removal 2-123
lnstallation 2-123
2 36 MEDALLIONS, BADGES AND TANK
EMBLEMS
Removal 2-124
lnstallation 2-124
ENGINE
3 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 3-1
3 2 SPECIFICATIONS
Specifications 3-3
3 3 SERVICE WEAR LIMITS
General 3-6
3 4 ENGINE OIL FLOW
Oil Feed 3-8
Тор End 3-8
Bottom End 3-10
Oil Retum 3-12
3 5 OIL PUMP OPERATION
General 3-13
Operation 3-1 3
3 6 BREATHER OPERATION
General 3-15
3 7 OIL PRESSURE
Oil Pressure lndicator Lamp 3-16
Oil Pressure Check 3-16
3 8 TROUBLESHOOTING
Diagnosing Valve Train Noise 3-17
Compression Test 3-17
Cylinder Leakdown Test 3-18
Diagnosing Smoking Engine ог High Oil Consumption 3-18
Check Before Cylinder Head Removal: 3-18
Check After Cylinder Head Removal: 3-18
3 9 HOW ТО USE THIS SECTION
Тор End Repair 3-19
Bottom End Repair 3-19
Typical Symptoms 3-19
3 10 ТОР END SERVICE
Engine in Chassis 3-20
Engine Removed from Chassis 3-21
3 11 САМ COMPARTMENT SERVICE
Replace Camshaft 3-22
Engine Removed From Chassis 3-23
3 12 STRIPPING MOTORCYCLE FOR
SERVICE
Procedure 3-24
Cam Compartment Service Only 3-24
Complete Тор End Service 3-24
3 13 ASSEMBLING MOTORCYCLE AFTER
SERVICE
Procedure 3-25
After Complete Тор End Service 3-25
After Cam Compartment Service Only 3-25
3 14 REMOVING ENGINE FROM CHASSIS
Procedure 3-26
3 15 INSTALLING ENGINE IN CHASSIS
Procedure 3-27
3 16 ТОР END OVERHAUL: DISASSEMBLY
General 3-29
Rocker Covers 3-29
Rocker Arm Support Plate 3-29
Pushrods, Lifters and Covers 3-31
Cylinder Head 3-31
Cylinder 3-32
Piston 3-33
3 17 BREATHER ASSEMBLY
DisassemЬly 3-35
Cleaning and lnspection 3-35
AssemЫy 3-35
TABLE OF CONTENTS
3 18 ROCKER ARM SUPPORT PLATE
DisassemЫy 3-36
Cleaning, lnspection and Repair 3-36
lnspection 3-36
Rocker Shaft Fit 3-36
Rocker Arm Shaft to Bushing 3-37
Replace Rocker Arm Bushings 3-37
AssemЫy 3-38
3 19 PUSHRODS, LIFTERS AND COVERS
DisassemЫy 3-39
Clean and lnspect 3-39
lnspect Lifters 3-39
AssemЫe Pushrod Cover 3-39
3 20 CYLINDER HEAD: ТWIN САМ 96, 103
lnspect Valve Sealing 3-41
DisassemЫy 3-41
Cleaning 3-42
1 nspection 3-42
Cylinder Head 3-42
Valve Guides 3-43
Valves 3-43
Valve Springs 3-43
Tapered Keepers 3-43
Valve Seats 3-43
Valve Guide Replacement 3-43
Removal 3-43
lnstallation 3-44
Valve and Seat Refacing 3-47
AssemЫy 3-49
3 21 CYLINDER HEAD: ТWIN САМ 110
Cylinder Head Repair 3-51
3 22 CYLINDER: ТWIN САМ 96, 103
Cleaning 3-52
lnspection 3-52
Deglazing Cylinder 3-54
Boring and Honing Cylinder 3-54
3 23 CYLINDER: ТWIN САМ 110
Cylinder Воге Finished Size 3-56
3 24 PISTON: ТWIN САМ 96, 103
DisassemЫy 3-57
Piston Rings 3-57
Cleaning 3-57
lnspection 3-57
AssemЬly 3-59
Checking Piston Ring Gap 3-59
lnstalling Piston Rings 3-59
3 25 PISTON: ТWIN САМ 11 О
Checking Piston Clearance 3-61
3 26 ТОР END OVERHAUL: ASSEMBLY
General 3-62
Piston 3-62
Cylinder 3-63
TABLE OF CONTENTS IX
TABLE OF CONTENTS
Cylinder Head 3-65
Pushrods, Lifters and Covers 3-68
Rocker Агm Support Plate 3-69
Вгеаthег and Rocker Соvег 3-70
3 27 САМ COMPARTMENT AND
COMPONENTS
Cam Support Plate and Соvег Removal 3-72
Ргераге Engine 3-72
Cam Chain and Sprockets Removal 3-72
Cam Support Plate Removal 3-73
Cam Support Plate Cleaning and lnspection 3-74
Oil Pressure Relief Valve 3-74
Cam Support Plate 3-74
Camshafts 3-7 4
Removal 3-74
lnstallation 3-75
Oil Pressure Relief Valve 3-76
Removal 3-76
lnspection 3-77
1 nstallation 3-77
Cam Needle Bearings 3-77
Removal 3-77
1 nstallation 3-79
Cam Support Plate and Соvег lnstallation 3-80
3 28 OIL P U M P
Removal 3-85
Cleaning and lnspection 3-85
lnstallation 3-86
3 29 CRAN KCASE DISASSEMBLY AND
REPAIR
Crankcase DisassemЫy 3-87
Cleaning and lnspection 3-87
Right Crankcase Half 3-88
Main Bearing Removal 3-88
Main Bearing lnstallation 3-88
Piston Jets Removal 3-89
Piston Jets lnstallation 3-89
Left Crankcase Half 3-89
Main Bearing Removal 3-89
Main Bearing lnstallation 3-90
Sprocket Shaft Bearing lnner Race 3-91
Removal 3-91
lnstallation 3-92
Cylinder Studs 3-94
Remove 3-94
lnstall 3-94
Pipe Plugs and Oil Fittings 3-94
Remove 3-94
lnstall 3-94
3 30 FLYWHEEL AND CON NECTING RODS
Symptoms 3-95
Overview 3-95
No Oil Pressure 3-95
Vibration 3-95
1 nspection 3-95
Measuring Crankshaft Runout 3-95
Crankshaft lnstalled 3-95
Х TABLE OF CONTENTS
Crankshaft Removed 3-96
3 31 CRAN KCASE ASSEMBLY
Cгankcase AssemЬly 3-97
3 32 OIL PAN
Removal 3-99
lnstallation 3-99
F UEL SYSTEM
4 1 FASTE N E R TORQU E VAL U ES
Fastener Torque Values in this Chapter 4-1
4 2 SPECI FICATIONS: F U E L SYSTEM
Specifications 4-5
4 3 AIR CLEAN ER ASSEMBLY: ALL BUT
FXDLS
Removal, AII But НО103 4-6
lnstallation, AII But НО103 4-7
Removal, НО103 4-7
lnstallation, НО103 4-8
Backplate AssemЫy: HDI Models 4-9
4 4 AIR CLEAN ER ASSEMBLY: FXDLS
DisassemЬle 4-10
AssemЫe 4-10
4 5 F U E L TANK
General 4-12
Removal 4-12
Cleaning and lnspection 4-13
1 nstal lation 4-14
Vарог Valve 4-14
4 6 ТWIST GRIP S ENSOR (TGS) : FXD LS
Remove 4-15
lnstall 4-15
4 7 ENGINE TEMPERATU RE SENSOR (ЕТ)
General 4-17
Removal 4-17
lnstallation 4-18
4 8 I N D U CTION MODULE: ALL BUT FXDLS
Removal 4-19
lnstallation 4-20
4 9 TH ROTTLE POSITION SENSOR {TPS):
ALL BUT FXDLS
General 4-21
Removal 4-21
lnstallation 4-21
4 1 О I NTAKE AIR TEMPERATU RE SENSOR
(IAT) : ALL BUT FXDLS
General 4-22
Removal 4-22
lnstallation 4-22
4 11 IDLE AIR CONTROL (IAC): ALL BUT
FXDLS
General 4-23
Removal 4-23
lnstallation 4-23
4 12 MANIFOLD ABSOLUTE PRESSURE
SENSOR (МАР): ALL BUT FXDLS
General 4-24
Removal 4-24
lnstallation 4-24
4 13 FUEL INJECTORS: ALL BUT FXDLS
General 4-25
Removal 4-25
lnstallation 4-25
4 14 INDUCTION MODULE: FXDLS
Removal 4-27
lnstallation 4-28
4 15 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR: FXDLS
Removal 4-29
lnstallation 4-29
4 16 FUEL INJECTORS: FXDLS
Removal 4-30
lnstallation 4-30
4 17 OXYGEN SENSOR
General 4-31
Removal 4-31
lnstallation 4-31
4 18 FUEL PUMP
General 4-32
Removal 4-32
DisassemЫy and AssemЫy 4-34
Fuel Filter 4-34
Regulator 4-34
lnlet Sock 4-35
Fuel Pump 4-36
1 nstal lation 4-36
4 19 FUEL PRESSURE TEST
General 4-39
Testing 4-39
4 20 EXHAUST SYSTEM
Removal: FXDB (all markets), FXDL (HDI, JPN) 4-41
DisassemЫy: FXDB (all markets), FXDL (HDI, JPN) 4-44
AssemЫy: FXDB (all markets), FXDL (HDI, JPN) 4-44
lnstallation: FXDB (all markets), FXDL (HDI, JPN) 4-44
FXDB (all but HDI, JPN) 4-44
FXDB, FXDL (HDI, JPN) 4-45
Removal: FXDLS, FXDF and FXDWG 4-46
lnstallation: FXDLS, FXDF and FXDWG 4-48
TABLE OF CONTENTS
Removal: FXDL (all but HDI, JPN) 4 -48
lnstallation: FXDL (all but HDI, JPN) 4-50
4 21 INTAKE LEAK TEST
General 4-51
Leak Tester 4 -51
Parts List 4-51
AssemЫe Tester 4-51
Adjust Tester 4-51
Procedure 4-51
4 22 EVAPORATIVE EMISSIONS CONTROL
General 4-53
Charcoal Canister 4 -55
Removal 4-55
lnstallation 4-55
DRIVE
5 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 5-1
5 2 SPECIFICATIONS: DRIVE
Specifications 5-2
5 3 PRIMARY CHAINCASE COVER
Removal 5-3
1 nstal lation 5-3
5 4 DRIVE COMPONENTS
Removal 5-5
lnstallation 5-7
5 5 PRIMARY CHAINCASE HOUSING
Removal 5-1 О
1 nspection 5-1 О
Mainshaft Bearing and Seal 5-10
Remove 5-1 О
lnstall 5-10
Mainshaft Bearing lnner Race 5-11
Remove 5-11
lnstall 5 -11
Shifter Shaft Bushing 5-11
lnstallation 5-12
5 6 CLUTCH
Removal and lnstallation 5-14
Clutch Pack Only 5-14
Partial DisassemЫy 5-14
Cleaning And lnspection 5-14
AssemЫy 5-15
Complete Clutch DisassemЫy 5-16
Ргераге 5-16
DisassemЫe 5-16
AssemЫe 5-17
Complete 5-17
5 7 TRANSMISSION SPROCKET
Removal 5-18
Clean and lnspect 5-19
TABLE OF CONTENTS XI
TABLE OF CONTENTS
lnstallation 5 -19
5 8 DRIVE BELT
Removal 5 -21
lnstallation 5 -21
TRANSMISSION
6 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 6-1
6 2 SPECIFICATIONS: TRANSMISSION
Specifications 6 -2
Service Wear Limits 6 -2
6 3 TRANSMISSION
Power Flow 6 -4
Neutral 6 -4
First Gear 6 -4
Second Gear 6 -4
Third Gear 6 -4
Fourth Gеаг 6 -4
Fifth Gear 6 -4
Sixth Gear 6 -4
6 4 SHIFTER LINКAGE
Shifter Rod Adjustment 6 -6
Forward Control Shifter Adjustment 6 -6
Mid-Control Shifter Adjustment 6 -6
6 5 CABLE CLUTCH RELEASE COVER
Removal and DisassemЫy 6 -7
Cleaning and lnspection 6 -7
AssemЫy and lnstallation 6 -8
6 6 TRANSMISSION ASSEMBLY
Removal 6 -9
DisassemЫy 6 -1 О
Shifter Cam/Shifter Forks 6-1 О
Mainshaft 6 -1 2
Countershaft 6 -1 4
Removing Bearing Housing Bearings 6-1 5
Cleaning and lnspection 6 -16
AssemЫy 6 -1 6
lnstalling Bearing Housing Bearings 6 -16
Countershaft 6 -1 6
Mainshaft 6 -1 7
Shifter Cam/Shifter Forks 6 -1 7
lnstallation 6 -1 9
6 7 MAIN DRIVE GEAR AND BEARING
Removal 6 -22
Clean and lnspect 6 -23
Replace Needle Bearings 6 -24
lnstallation 6 -25
lnstalling Main Drive Gear Bearing 6 -25
lnstalling Main Drive Gear 6 -26
lnstalling Main Drive Gear Large Seal 6 -26
XII TABLE OF CONTENTS
6 8 TRANSMISSION CASE
Removal 6 -29
lnstallation 6 -29
DisassemЬle 6 -30
Remove Shifter Pawl Lever 6 -30
Clean and lnspect 6 -30
AssemЬle 6 -31
Replace Countershaft Needle Bearing 6 -31
lnstall Shifter Pawl Lever 6 -31
ELECTRICAL
7 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 7 -1
7 2 SPECIFICATIONS: ELECTRICAL
Specifications 7 -4
7 3 ELECTRICAL CADDY
Removal 7-5
lnstallation 7 -7
7 4 ELECTRONIC CONTROL MODULE (ЕСМ)
General 7-8
Replacement 7 -8
Removal 7 -8
1 nstallation 7 -8
7 5 BODY CONTROL MODULE (ВСМ)
General 7-9
Removal 7-9
lnstallation 7 -1 О
7 6 SECURIТY SIREN
Removal 7- 1 1
lnstallation 7-1 1
7 7 SPARK PLUG CABLES
lnspect Spark Plug СаЫеs 7 -1 2
Removal 7 -1 2
lnstallation 7 -1 2
7 8 FUSES
General 7 -1 3
Replacement 7 -1 3
7 9 IGNITION SWITCH
Removal 7 -14
AII but FXDL, FXDLS 7- 1 4
FXDL 7 -14
lnstallation 7- 1 5
AII but FXDL, FXDLS 7 -1 5
FXDL 7 – 1 5
7 10 ВАПЕRУ TRAY AND ВАПЕRУ
CABLES
Battery Тгау 7 -16
Removal 7 -1 6
lnstallation 7 -1 6
Battery СаЫеs 7-17
Routing 7-17
7 11 STARTER
General 7-19
Removal 7-19
Drive AssemЫy 7-19
DisassemЫy 7-19
lnspection 7-20
AssemЫy 7-20
Solenoid 7 -20
Remove Cover and Plunger 7-20
Short Post Contact: Starter 7-21
Long Post Contact: Battery Positive 7-21
lnstall Plunger and Cover 7-22
lnstallation 7-22
7 12 HEADLAMP
General 7 -23
Bulb Removal 7-23
Single Bulb Headlamp 7-23
Dual Bulb Headlamp 7-24
Bulb lnstallation 7-25
Headlamp AssemЫy: AII But FXDL 7-25
Removal 7-25
lnstallation 7-25
Headlamp AssemЫy: FXDL 7 -25
Removal 7-25
lnstallation 7-25
Headlamp Visor: FXDL 7-26
Removal 7-26
lnstallation 7-26
7 13 TAIL LAMP
General 7-28
Tail Lamp Bulb Replacement: FXDL 7-28
Base Replacement: FXDL 7-28
Base Replacement: FXDWG, AII But U S 7-29
Tail Lamp Replacement: FXDF 7-30
Tail Lamp Removal 7-30
Tail Lamp lnstallation 7-30
License Plate Lamp Replacement 7-30
Tail Lamp/License Plate Bracket: FXDB, FXDLS, AII But
U S 7-32
DisassemЫe 7-32
AssemЫe 7-32
7 14 TURN SIGNALS
Turn Signal Bulb Replacement: Bullet Style 7-33
Front Lamp Housing Replacement 7-33
Rear Lamp Housing Replacement 7-35
7 15 CRANK POSITION SENSOR (СКР)
General 7-37
Removal 7-37
lnstallation 7-37
7 16 AUTOMATIC COMPRESSION RELEASE
(ACR)
General 7-38
Removal 7-38
TABLE OF CONTENTS
lnstallation 7-38
7 17 VOLTAGE REGULATOR
Removal 7-40
lnstallation 7-40
7 18 ALTERNATOR
Removal 7-41
Cleaning and lnspection 7-41
lnstallation 7-41
7 19 FUEL GAUGE
General 7-43
Removal 7-43
7 20 FUEL GAUGE SENDER
Removal 7-44
lnstallation 7-45
7 21 INSTRUMENTS : FXDF
Speedometer 7-4 7
Removal 7-47
lnstallation 7-47
7 22 INSTRUMENTS: FXDB, FXDWG
Removal 7-48
lnstallation 7 -48
7 23 INSTRUMENTS: FXDL AND FXDLS
Removal 7-50
1 nstallation 7-50
7 24 VEHICLE SPEED SENSOR (VSS)
General 7 -51
Removal 7 -51
lnstallation 7-51
7 25 WHEEL SPEED SENSORS
Front Wheel Speed Sensor (WSS) 7-52
Removal 7-52
lnstallation 7-52
Rear Wheel Speed Sensor (WSS) 7-53
Removal 7-53
lnstallation 7-54
7 26 INDICATOR LAMPS
Removal 7-56
FXDF 7-56
FXDB, FXDWG 7-56
lnstallation 7-57
FXDF 7-57
FXDLS, FXDB, FXDWG, FXDF 7-57
7 27 NEUTRAL SWITCH
General 7-58
Removal 7 -58
lnstallation 7-58
7 28 OIL PRESSURE SWITCH
General 7-59
TABLE OF CONTENTS XIII
TABLE OF CONTENTS
Removal 7-59
lnstallation 7-59
7 29 REAR STOP LAMP SWITCH
General 7 -60
Removal 7-60
lnstallation 7-60
7 30 HORN
lnspection 7-61
Replacement: AII But FXDL and FXDLS 7-61
Replacement: FXDL and FXDLS 7-62
7 31 MAIN WIRING HARNESS
General 7-63
Removal 7-63
1 nstallation 7-65
7 32 HANDLE8AR CONTROL MODULES
General 7-69
Repair Procedures 7-69
7 33 LEFT HANDLE8AR CONTROL
MODULE: ALL 8UT FXDLS
Removal 7-70
Clutch Switch Replacement 7-70
lnstallation 7-70
7 34 RIGHT HANDLE8AR CONTROL
MODULE: ALL 8UT FXDLS
Removal 7-72
Front Brake Switch Replacement 7-73
lnstallation 7-73
7 35 LEFT HANDLE8AR CONTROL
MODULE: FXDLS
Removal 7-75
lnstallation 7-75
7 36 RIGHT HANDLE8AR CONTROL
MODULE: FXDLS
Removal 7-77
lnstallation 7-77
7 37 H-DSSS MAINTENANCE
Fob Battery 7-79
Battery Replacement Schedule 7-79
Battery Replacement 7-79
Fob Battery 7-79
Battery Replacement Schedule 7-79
Battery Replacement 7-79
Smart Siren {lf lnstalled} 7-79
Battery Replacement Schedule 7-79
XIV TABLE OF CONTENTS
Battery Replacement 7-79
7 38 PERSONAL IDENTIFICATION NUM8ER
(PIN)
General 7-81
Changing The PIN 7-81
Modifying an Existing PIN 7-81
7 39 H-DSSS ACTUATION
Sidecar Configuration 7-83
Activation 7 -83
Fob Assignment 7-83
APPENDIX А WIRING
А 1 CONNECTORS
Connector Locations A-1
F u nction/Location А-1
Place and Color A-1
Connector Number A-1
Repair lnstructions A-1
д 2 WIRING DIAGRAMS
Wiring Diagram lnformation A-4
Wire Color Codes A-4
Wiring Diagram Symbols А-4
2017 Dyna Wiring Diagrams А-6
APPENDIX В REFERENCE
8 1 LENGTH CONVERSION
Conversion ТаЫе 8-1
8 2 FLUID CONVERSION
United States System В-2
Metric System В-2
British lmperial System 8-2
8 3 TORQUE CONVERSION
United States System 8-3
Metric System В-3
8 4 GLOSSARY
Acronyms and Abbreviations В-4
REFERENCE M ATERIAL
TOOLS I
TORQUE VALUES VII
INDEX XXI
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