Dyna FDX Maintenance Manual

Page 1

MAINTENANCE 1

able Of Contents

SUBJECT PAGE NO.

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Fuel and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.3 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.4 Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.5 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1.7 Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

1.8 Brake Pads and Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1.9 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

1.10 Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

1.11 Primary Chaincase Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

1.12 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

1.13 Transmission Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

1.14 Rear Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

1.15 Rear Belt and Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

1.16 Suspension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

1.17 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

1.18 Front Fork Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

1.19 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1.20 Air Cleaner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

1.21 Cable and Chassis Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41

1.22 Throttle Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

1.23 Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

1.24 Headlamp Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

1.25 Critical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

1.26 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48

1.27 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

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11WARNING1WARNING

GENERAL 1.1

SERVICING A NEW

SHOP PRACTICES

MOTORCYCLE

Repair Notes

NOTE

General maintenance practices are given in this section.

11WARNING1WARNING

Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a).

Service operations to be performed before customer delivery are speciﬁed in the applicable model year PREDELIVERY AND SETUP MANUAL.

The performance of new motorcycle initial service is required to keep warranty in force and to ensure proper emissions systems operation.

After a new motorcycle has been driven its ﬁrst 1000 miles (1600 km), and at every 5000 mile (8000 km) interval thereafter, have a Harley-Davidson dealer perform the service operations listed under 1.3 MAINTENANCE SCHEDULE.

SAFE OPERATING MAINTENANCE

CAUTION

●

Do not attempt to retighten engine head bolts. Retightening can cause engine damage.

●

Repair = Disassembly/Assembly.

●

Replace = Removal/Installation.

All special tools and torque values are noted at the point of use.

All required parts or materials can be found in the appropriate PA RTS CATALOG.

Safety

Safety is always the most important consideration when performing any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. Protect yourself and bystanders with approved eye protection. Don’t just do the job – do the job safely.

Removing Parts

Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts. The lengths of chains or cables from the hoist to the part should be equal and parallel and should be positioned directly over the center of the part. Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air.

During the initial 1000 mile (1600 km) break-in

●

period, use only Harley-Davidson 20W50 engine oil. Failure to use the recommended oil will result in improper break-in of the engine cylinders and piston rings.

A careful check of certain equipment is necessary after periods of storage, and frequently between regular service intervals, to determine if additional maintenance is required.

Check:

1. Tires for abrasions, cuts and correct pressure.

2. Secondary drive belt for proper tension and condition.

3. Brakes, steering and throttle for responsiveness.

4. Brake ﬂuid level and condition. Hydraulic lines and ﬁttings for leaks. Also, check brake pads and rotors for wear.

5. Cables for fraying, crimping and free operation.

6. Engine oil and transmission ﬂuid levels.

7. Headlamp, passing lamp, tail lamp, brake lamp, horn and turn signal operation.

Always check the capacity rating and condition of hoists, slings, chains or cables before use. Failure to do so could lead to an accident which could result in death or serious injury.

Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed.

When removing hoses, wiring or tubes, always tag each part to ensure proper installation.

Cleaning

If you intend to reuse parts, follow good shop practice and thoroughly clean the parts before assembly. Keep all dirt out of parts; the unit will perform better and last longer. Seals, ﬁlters and covers are used in this vehicle to keep out environmental dirt and dust. These items must be kept in good condition to ensure satisfactory operation.

Clean and inspect all parts as they are removed. Be sure all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Be sure the part is clean when it is installed.

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Always clean around lines or covers before they are removed. Plug, tape or cap holes and openings to keep out dirt, dust and debris.

Always verify cleanliness of blind holes before assembly. Tightening a screw with dirt, water or oil in the hole can cause castings to crack or break.

Disassembly and Assembly

Always assemble or disassemble one part at a time. Do not work on two assemblies simultaneously. Be sure to make all necessary adjustments. Recheck your work when ﬁnished. Be sure that everything is done.

Operate the vehicle to perform any ﬁnal check or adjustments. If all is correct, the vehicle is ready to go back to the customer.

REPAIR AND REPLACEMENT PROCEDURES

Hardware and Threaded Parts

Install helical thread inserts when inside threads in castings are stripped, damaged or not capable of withstanding speciﬁed torque.

Replace bolts, nuts, studs, washers, spacers and small common hardware if missing or in any way damaged. Clean up or repair minor thread damage with a suitable tap or die.

Replace all damaged or missing lubrication ﬁttings. Use Teﬂon pipe sealant on pipe ﬁtting threads.

Coat bearings with clean oil. Wrap bearings in clean paper.

Be sure that the chamfered side of the bearing always faces the shoulder (when bearings installed against shoulders). Lubricate bearings and all metal contact surfaces before pressing into place. Only apply pressure on the part of the bearing that makes direct contact with the mating part.

Always use the proper tools and ﬁxtures for removing and installing bearings.

Bearings do not usually need to be removed. Only remove bearings if necessary.

Bushings

Do not remove a bushing unless damaged, excessively worn or loose in its bore. Press out bushings that must be replaced.

When pressing or driving bushings, be sure to apply pressure in line with the bushing bore. Use a bearing/bushing driver or a bar with a smooth, ﬂat end. Never use a hammer to drive bushings.

Inspect the bushing and the mated part for oil holes. Be sure all oil holes are properly aligned.

Gaskets

Always discard gaskets after removal. Replace with kets. Unless otherwise instructed, never use the same gasket twice. Be sure that gasket holes match up with holes in the mating part. But be aware that sections of a gasket may be used to seal passages.

new

gas-

Lip Type Seals

Wiring, Hoses and Lines

Replace hoses, clamps, electrical wiring, electrical switches or fuel lines if they do not meet speciﬁcations.

Instruments and Gauges

Replace broken or defective instruments and gauges. Replace dials and glass that are so scratched or discolored that reading is difﬁcult.

Bearings

Anti-friction bearings must be handled in a special way. To keep out dirt and abrasives, cover the bearings as soon as they are removed from the package.

Wash bearings in a non-ﬂammable cleaning solution. Knock out packed lubricant inside by tapping the bearing against a wooden block. Wash bearings again. Cover bearings with clean material after setting them down to dry. Never use compressed air to dry bearings.

Lip seals are used to seal oil or grease and are usually installed with the sealing lip facing the contained lubricant. Seal orientation, however, may vary under different applications.

Seals should not be removed unless necessary. Only remove seals if required to gain access to other parts or if seal damage or wear dictates replacement.

Leaking oil or grease usually means that a seal is damaged. Replace leaking seals to prevent overheated bearings.

Always discard seals after removal. Do not use the same seal twice.

O-Rings (Preformed Packings)

Always discard O-rings after removal. Replace with rings. To prevent leaks, lubricate the O-rings before installation. Apply the same type of lubricant as that being sealed. Be sure that all gasket, O-ring and seal mating surfaces are thoroughly clean before installation.

new

O-

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Gears

Always check gears for damaged or worn teeth.

Lubricate mating surfaces before pressing gears on shafts.

Shafts

If a shaft does not come out easily, check that all nuts, bolts or retaining rings have been removed. Check to see if other parts are in the way before using force.

Shafts ﬁtted to tapered splines should be very tight. If shafts are not tight, disassemble and inspect tapered splines. Discard parts that are worn. Be sure tapered splines are clean, dry and free of burrs before putting them in place. Press mating parts together tightly.

Clean all rust from the machined surfaces of new parts.

Part Replacement

Always replace worn or damaged parts with

new

parts.

CLEANING

Part Protection

Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions. Use a grease-proof barrier material. Remove the rubber part if it cannot be properly protected.

Cleaning Process

Any cleaning method may be used as long as it does not result in parts damage. Thorough cleaning is necessary for proper parts inspection. Strip rusted paint areas to bare metal before repainting.

Rust or Corrosion Removal

TOOL SAFETY

Air Tools

Always use approved eye protection equipment when

●

performing any task using air-operated tools.

●

On all power tools, use only recommended accessories with proper capacity ratings.

●

Do not exceed air pressure ratings of any power tools.

●

Bits should be placed against work surface before air hammers are operated.

Disconnect the air supply line to an air hammer before

●

attaching a bit. Never point an air tool at yourself or another person.

●

Protect bystanders with approved eye protection.

Wrenches

Never use an extension on a wrench handle.

●

If possible, always pull on a wrench handle and adjust your stance to prevent a fall if something lets go.

●

Never cock a wrench. Never use a hammer on any wrench other than a STRIK-

●

ING FACE wrench. Discard any wrench with broken or battered points.

●

Never use a pipe wrench to bend, raise or lift a pipe.

Pliers/cutters/prybars

Plastic- or vinyl-covered pliers handles are not intended

●

to act as insulation; don’t use on live electrical circuits. Don’t use pliers or cutters for cutting hardened wire

●

unless they were designed for that purpose.

●

Always cut at right angles.

●

Don’t use any prybar as a chisel, punch or hammer.

Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use bufﬁng crocus cloth on highly polished parts that are rusted.

Bearings

Clean open bearings by soaking them in a petroleum cleaning solution. Never use a solution that contains chlorine.

Let bearings stand and dry. Do not dry using compressed air. Do not spin bearings while they are drying.

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Hammers

●

Never strike one hammer against a hardened object, such as another hammer.

Always grasp a hammer handle ﬁrmly, close to the end.

●

Strike the object with the full face of the hammer.

●

Never work with a hammer which has a loose head. Discard hammer if face is chipped or mushroomed.

●

Wear approved eye protection when using striking tools.

●

Protect bystanders with approved eye protection.

Punches/Chisels

●

Never use a punch or chisel with a chipped or mushroomed end; dress mushroomed chisels and punches with a ﬁle.

Hold a chisel or a punch with a tool holder if possible.

●

When using a chisel on a small piece, clamp the piece ﬁrmly in a vise and chip toward the stationary jaw.

●

Wear approved eye protection when using these tools. Protect bystanders with approved eye protection.

●

Screwdrivers

●

Don’t use a screwdriver for prying, punching, chiseling, scoring or scraping.

Use the right type of screwdriver for the job; match the tip

●

to the fastener. Don’t interchange POZIDRIV®, PHILLIPS® or REED

●

AND PRINCE screwdrivers. Screwdriver handles are not intended to act as insula-

●

tion; don’t use on live electrical circuits. Don’t use a screwdriver with rounded edges because it

●

will slip – redress with a ﬁle.

Ratchets and Handles

●

Periodically clean and lubricate ratchet mechanisms with a light grade oil. Do not replace parts individually; ratchets should be rebuilt with the entire contents of service kit.

●

Never hammer or put a pipe extension on a ratchet or handle for added leverage.

●

Always support the ratchet head when using socket extensions, but do not put your hand on the head or you may interfere with the action of its reversing mechanism.

●

When breaking loose a fastener, apply a small amount of pressure as a test to be sure the ratchet’s gear wheel is engaged with the pawl.

Sockets

●

Never use hand sockets on power or impact wrenches. Select the right size socket for the job.

●

Never cock any wrench or socket.

●

Select only impact sockets for use with air or electric impact wrenches.

Replace sockets showing cracks or wear.

●

Keep sockets clean.

●

Always use approved eye protection when using power or impact sockets.

Storage Units

Don’t open more than one loaded drawer at a time.

●

Close each drawer before opening up another. Close lids and lock drawers and doors before moving

●

storage units.

●

Don’t pull on a tool cabinet; push it in front of you.

●

Set the brakes on the locking casters after the cabinet has been rolled to your work.

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FUEL AND OIL 1.2

FUEL

11WARNING1WARNING

Use care when refueling. Pressurized air in fuel tank can force gasoline to escape through ﬁller tube. Gasoline is extremely ﬂammable and highly explosive, which could result in death or serious injury. (00029a)

11WARNING1WARNING

Avoid spills. Slowly remove ﬁller cap. Do not ﬁll above bottom of ﬁller neck insert, leaving air space for fuel expansion. Secure ﬁller cap after refueling. Gasoline is extremely ﬂammable and highly explosive, which could result in death or serious injury. (00028a)

Use a good quality unleaded gasoline (91 pump octane or higher). Octane ratings are usually shown on the gas pump.

GASOLINE BLENDS

ENGINE OIL

Use the proper grade of oil for the lowest temperature expected before the next oil change.

If it is necessary to add oil and Harley-Davidson oil is not available, use an oil certiﬁed for diesel engines. Acceptable diesel engine oil designations include:

CF-4

●

CG-4

●

CH-4 CI-4

●

The preferred viscosities for the diesel engine oils, in descending order, are:

●

20W-50

●

15W-40 10W-40

●

At the ﬁrst opportunity, see a Harley-Davidson dealer to change back to 100 percent Harley-Davidson oil.

See 1.4 ENGINE OIL AND FILTER for all service information.

WINTER LUBRICATION

CAUTION

Using gasoline that has an alcohol additive, such as methanol, may cause fuel system rubber components’ failure and/or engine damage.

Harley-Davidson motorcycles were designed to give the best performance using unleaded gasoline. Some fuel suppliers sell gasoline/alcohol blends as a fuel. The type and amount of alcohol added to the fuel is important.

●

DO NOT USE GASOLINES CONTAINING METHANOL. Using gasoline/methanol blends will result in starting and driveability deterioration and damage to critical fuel system components.

●

ETHANOL is a mixture of 10% ethanol (Grain alcohol) and 90% unleaded gasoline. Gasoline/ethanol blends can be used in your motorcycle if the ethanol content does not exceed 10%.

REFORMULATED OR OXYGENATED GASOLINES

●

(RFG): “Reformulated gasoline” is a term used to describe gasoline blends that are speciﬁcally designed to burn cleaner than other types of gasoline. Your motorcycle will run normally using this type of gas.

Combustion in an engine produces water vapor. During starting and warm-up in cold weather, especially in freezing temperatures, the vapor condenses to water before the crankcase is hot enough to exhaust it through the breather system. If the engine is run long enough for the crankcase to become thoroughly heated, the water returns to vapor and is then exhausted.

An engine used for only short trips, and seldom allowed to thoroughly warm up, accumulates increasing amounts of water in the oil pan. Water mixed with oil forms a sludge that causes accelerated engine wear. In freezing temperatures, the water becomes slush or ice, which may clog oil lines and result in engine failure.

Always change the engine oil more often in winter. If the engine is used for short runs, change the oil even more frequently. The farther below freezing the temperature drops the more often the oil should be changed.

You may ﬁnd that some gasoline blends adversely affect the starting, driveability or fuel efﬁciency of your bike. If you experience one or more of these problems, we recommend you try a different brand of gasoline or gasoline with a higher octane rating.

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MAINTENANCE SCHEDULE 1.3

Table 1-1. Regular Service Intervals For Dyna Models

1000

5000

10,000

15,000

20,000

24,000

ITEM SERVICED PROCEDURE

1600

8000

16,000

Engine oil and ﬁlter Replace XXXXXX Oil lines and brake system Inspect for leaks XXXXXX 1 Air cleaner Inspect, service as required XXXXXX Tires Check pressure, inspect tread XXXXXX Wheel spokes Check tightness X X X 1, 4 Primary chaincase lubricant Replace XXXXXX Tr ansmission lubricant Replace XXXXXX Clutch Check adjustment XXXXXX 1 Rear belt and sprockets Inspect, adjust belt XXXXXX 1 Throttle, brake and clutch con-

Check, adjust and lubricate XXXXXX1, 4

trols Jiffy stand Inspect and lubricate X X X 1 Fuel lines and ﬁttings Inspect for leaks XXXXXX1, 4 Fuel tank ﬁlter screen Replace X 1 Brake ﬂuid Check levels and condition XXXXXX 5 Brake pads and discs Inspect for wear XXXXXX Spark plugs Inspect X X X X

Replace X X

Electrical equipment and

Check operation XXXXXX

switches Engine idle speed Check adjustment XXXXXX 1 Front fork oil Replace X 1 Steering head bearings Adjust X X X 1, 2 Rear fork bearings Inspect every 30,000 mi (48,000 km) 1 Primary chaincase bearing Replace every 15,000 mi (24,000 km) 6 Critical fasteners Check tightness X X X 1 Engine mounts and stabilizer

Inspect X X 1

links Battery Check battery and clean connections 3 Road test Verify component and system functions XXXXXX

32,000

25,000

40,000

NOTES

NOTES:

1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualiﬁed.

2. Disassemble, lubricate and inspect every 30,000 miles (48,000 km).

3. Perform annually.

4. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.

5. Replace D.O.T. 4 HYDRAULIC BRAKE FLUID and ﬂush system every two years.

6. See an authorized Harley-Davidson dealer.

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Table 1-2 Quick Reference Maintenance Chart

ITEM SERVICED SPECIFICATION DATA

Drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)

Oil capacity 3 qt. (2.4 L)

Engine oil and ﬁlter

Primary chain lubricant

Clutch adjustment

Tr ansmission lubricant

Filter Hand tighten 1/2-3/4 turn after gasket contact

Chrome ﬁlter part number 63798-99

Black ﬁlter part number 63731-99

Lubricant capacity 32 oz. (0.95 liters)

Primary chaincase drain plug torque 36-60

Free play at adjuster screw 1/2-1 turn

Adjuster screw locknut torque 72-120

Free play at hand lever 1/16-1/8 (1.6-3.2 mm)

Clutch inspection cover torque 84-108

Lubricant level Check with motorcycle at normal operating tem-

Lubricant capacity 32 oz (0.95 liters)

Tr ansmission drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)

in-lbs

(4.1-6.8 Nm)

in-lbs

(8.1-13.6 Nm)

in-lbs

(9.5-12.2 Nm)

perature and parked on jiffy stand. Remove and wipe off dipstick. Place dipstick in ﬁller hole with ﬁller plug resting on threads and remove. Lubricant level should be between upper and lower ends of the oil level indicator marks on the dipstick.

Filler/check plug torque 25-75

Pressure for solo rider Front: 30 psi (207 kPA)

Rear: 36 psi (248 kPA)

Tire condition and pressure

Wheel spokes Spoke nipple torque 40-50

Brake ﬂuid reservoir level

Brake pad linings and discs

Pressure for rider and passenger Front: 30 psi (207 kPA)

Rear: 40 psi (276 kPA)

Wear Replace tire if 1/32 in. (0.8 mm) or less of tread

pattern remains

D.O.T. 4 hydraulic brake ﬂuid part numbers

Proper ﬂuid level 1/8-1/4 in. (3.2-6.4 mm) below gasket surface

Master cylinder reservoir cover torque 6-8

Minimum brake pad thickness 0.04 in. (1.02 mm)

Minimum brake disc thickness See stamp on side of disc

99953-99A (12 oz.)

in-lbs

(2.8-8.5 Nm)

in-lbs

(4.5-5.6 Nm)

(0.7-0.9 Nm)

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Table 1-2 Quick Reference Maintenance Chart

ITEM SERVICED SPECIFICATION DATA

Upward measurement force applied at midpoint of bottom belt strand

Drive belt

Air cleaner

Clutch and throttle cables

Spark plugs

Engine idle speed Idle speed 950-1050 RPM

Front fork oil

Measure belt deﬂection with motorcycle cold and the approximate weight of the owner on motorcycle.

Air cleaner cover bracket screw torque 20-40

Air cleaner cover screw torque 36-60

Adhesive for air cleaner cover screw LOCTITE THREADLOCKER 243

Lubricant SUPER OIL Part No. 94968-85TV (1/4 ﬂ. oz.)

Handlebar switch housing screw torque 35-45

Type HD-6R12

Gap 0.038-0.043 in. (0.97-1.09 mm)

Torque 12-18 ft-lbs (16.3-24.4 Nm)

Amount See section

Type

10 lb. (4.5 kg)

5/16-3/8 in. (7.9-9.5 mm)

in-lbs

(2.3-4.5 Nm)

in-lbs

(4.1-6.8 Nm)

Part No. 99642-97 (6 ml)

in-lbs

(4.0-5.1 Nm)

2.18 FRONT FORK

HYDRAULIC FORK OIL (TYPE E) Part No. 99884-80 (16 oz.)

Battery Battery terminal torque 60-96

in-lbs

(6.8-10.9 Nm)

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ENGINE OIL AND FILTER 1.4

CHECKING AND ADDING OIL

CAUTION

Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine. (00185a)

See Figure 1-1. Check engine oil level:

●

As part of the pre-ride inspection. At each fuel ﬁll

●

At every scheduled service interval.

Type of Oil

Refer to Ta ble 1-3. Use the proper grade of oil for the lowest temperature expected before the next oil change. See 1.2

FUEL AND OIL for speciﬁc information regarding winter

needs. If it is necessary to add oil and Harley-Davidson oil is not

available, use an oil certiﬁed for diesel engines. Acceptable diesel engine oil designations include CF-4, CG-4, CH-4 and CI-4. The preferred viscosities for the diesel engine oils, in descending order, are 20W-50, 15W-40 and 10W-40. At the ﬁrst opportunity, see a Harley-Davidson dealer to change back to 100 percent Harley-Davidson oil.

Checking With Cold Engine

1. See Figure 1-1. Unscrew and remove engine oil ﬁller cap with attached dipstick. Wipe dipstick clean.

2. Reinstall ﬁller cap. Turn ﬁller cap clockwise until it stops.

3. See Figure 1-2. Again, unscrew and remove ﬁller cap and check oil level on dipstick. If oil level in pan is below lower mark on dipstick, add enough Harley-Davidson oil to bring level up between lower mark (1) and cold check level (2) on dipstick.

4. Replace ﬁller cap and screw in securely.

Figure 1-1. Checking Engine Oil Level

11571a

For cold check level do not exceed

this point when ﬁlling with oil.

1 2

1. Lower arrow (add oil)

2. Cold check level

3. Upper arrow (hot check level)

Figure 1-2. Engine Oil Dipstick

NOTE

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Checking With Warm Engine

Ride motorcycle until engine is warmed up to operating temperature, then do the following.

1. Idle motorcycle on jiffy stand for 1-2 minutes.

2. Shut motorcycle off and with motorcycle leaning on jiffy stand on level ground, unscrew and remove engine oil ﬁller cap with attached dipstick. Wipe dipstick clean.

3. Reinstall ﬁller cap. Turn ﬁller cap clockwise until it stops.

4. See Figure 1-2. Again, unscrew and remove ﬁller cap and check oil level on dipstick. If oil level in pan is below lower mark on dipstick, add enough Harley-Davidson oil to bring level up between lower mark (1) and cold check level (2) on dipstick.

5. Replace ﬁller cap and screw in securely.

6. Add oil, if required, to FULL mark (3). Do not overﬁll.

CHANGING OIL AND FILTER

PART NO.

HD-42311 or HD-44067

Oil ﬁlter wrench

SPECIALTY TOOL

Front of motorcycle

d0442x3x

1. Engine oil drain plug and O-ring @ 14-21 ft-lbs (19.0-28.5 Nm)

2. Transmission drain plug

Figure 1-3. Oil Pan

h42311 hd44067

NOTES

●

If the motorcycle is ridden hard, under dusty conditions, or in cold weather, the oil and ﬁlter should be changed more often.

●

All Dyna models are shipped from the factory with SAE 20W50 Harley-Davidson 360 Motor Oil.

●

All Dyna models come equipped from the factory with a premium 5 micron synthetic media oil ﬁlter, Part No. 63798-99 (Chrome) or 63731-99 (Black). These are the only recommended replacement ﬁlters.

1. Ride motorcycle until engine is warmed up to normal operating temperature.

2. See Figure 1-1. Unscrew and remove engine oil ﬁller cap with attached dipstick.

3. See Figure 1-3. Remove the engine oil drain plug with Oring (1). Allow oil to drain into a suitable container.

Figure 1-4. Oil Filter Wrench

Part No. HD-42311 (left), HD-44067 (right)

1-10 2006 Dyna: Maintenance

Page 13

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d0384x1x

CAUTION

Use Harley-Davidson oil ﬁlter wrench for ﬁlter removal, which can prevent damage to crankshaft position sensor and/or sensor cable.

Note On vehicles equipped with forward controls, shift linkage may have to be removed to provide enough clearance to remove and install oil ﬁlter.

4. See Figure 1-4. Remove the oil ﬁlter using the OIL FIL-

TER WRENCH. Clean the oil ﬁlter mount ﬂange of any old gasket material.

5. See Figure 1-5. Lube the gasket on

engine oil and install to 3/4 turn after gasket contacts ﬁlter mounting surface. Do NOT use oil ﬁlter wrench for oil ﬁlter installation.

6. See Figure 1-3. Install oil pan drain plug (1).

a. Inspect O-ring for tears or damage. Replace if

required. Wipe any foreign material from plug.

b. Install O-ring and drain plug. Tighten to 14-21 ft-lbs

(19.0-28.5 Nm).

7. See Figure 1-1. Fill oil pan with the correct amount of oil.

Use the proper grade of oil for the lowest temperature expected before next oil change. Refer to Ta ble 1-3.

a. Use 2.5 quarts (2.4 liters) of engine oil for a wet

capacity reﬁll.

b. Use 3.0 quarts (2.7 liters) for a dry capacity reﬁll.

Use wet capacity for engines that have just had the oil drained. Use dry capacity for engines that have been disassembled, cleaned in solvent and dried.

8. Check engine oil level using cold check procedure.

9. Start engine and carefully check for oil leaks around

drain plug and oil ﬁlter.

10. Check engine oil level using hot check procedure.

new

ﬁlter. Hand tighten oil ﬁlter 1/2

NOTE

new

oil ﬁlter with

Figure 1-5. Lubing New Oil Filter

Table 1-3. Recommended Oil Grades

HARLEY-DAVIDSON

TYPE

VISCOSITY

HARLEY-DAVID-

SON RATING

H.D. Multi-Grade SAE 10W40 HD 360 Below 40° F (4° C) Excellent H.D. Multi-Grade SAE 20W50 HD 360 Above 40° F (4° C) Good

H.D. Regular Heavy SAE 50 HD 360 Above 60° F (16° C) Poor

H.D. Extra Heavy SAE 60 HD 360 Above 80° F (27° C) Poor

LOWEST AMBIENT

TEMP °F

2006 Dyna: Maintenance 1-11

COLD WEATHER STARTS

BELOW 50°F

Page 14

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BATTERY MAINTENANCE 1.5

GENERAL

11WARNING1WARNING

Never remove warning label attached to top of battery. Failure to read and understand all precautions contained in warning, could result in death or serious injury. (00064a)

11WARNING1WARNING

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

All AGM batteries are permanently sealed, maintenance-free, valve-regulated, lead/calcium and sulfuric acid batteries. The batteries are shipped pre-charged and ready to be put into service. Do not attempt to open these batteries for any reason.

d0424x1x

1. Warning label

2. Positive terminal cover

Figure 1-6. Battery

Table 1-4. Battery Electrolyte Antidotes

CONTACT

External Flush with water.

Internal Drink large quantities of milk or water,

followed by milk of magnesia, vegetable oil or beaten eggs. Call doctor immediately.

Eyes Flush with water, get immediate medical

attention.

d0425a1x

Contents

are Corrosive.

Safety Glasses.

SOLUTION

Wear

Contents

are Explosive.

NOTE

See 8.12 BATTERY for charging and testing information.

Keep

Flames Away.

Read

Instructions.

Keep Away

From Children.

1-12 2006 Dyna: Maintenance

Figure 1-7. Battery Warning Label

Page 15

HOME

11WARNING1WARNING

DISCONNECTION AND REMOVAL

1. Remove seat.

11WARNING1WARNING

Disconnect negative (-) battery cable ﬁrst. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

2. See Figure 1-8. Remove lower fastener (1).

3. Pivot cover (2) outward and lift to disengage slots on

cover from projections on battery tray (3).

4. Unthread and remove battery negative cable from nega-

tive battery terminal (4).

5. Unbolt and remove battery positive cable from positive

(+) battery terminal (5).

6. Remove battery strap (6).

7. Remove battery from tray.

INSTALLATION AND CONNECTION

k00471g

1. Screw

2. Cover

3. Battery tray

4. Negative battery terminal

5. Positive battery terminal

6. Battery strap

7. Battery terminal cover

Figure 1-8. Battery Assembly

MADE IN

E D

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h t

s l e

a c

r a

l e

t p a

e a m

a n i

m r

h s

h e

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t h

n c

h u

r o

f n

a a f

e c

g r

r r u

c l

b c e

e r t

s i

i u

c r

e u t

t p

w e

f t

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f o

n m h

i r d

e c

t a

t l

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a h r

n s

e i m

y u

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u j

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r e a

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d r

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a p

o r

1234567890

m i

L I M

O N T R

A P

CAUTION

Do not over-tighten bolts on battery terminals. Use recommended torque values. Over-tightening battery terminal bolts could result in damage to battery terminals. (00216a)

11WARNING1WARNING

Connect positive (+) battery cable ﬁrst. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

NOTE

Check that battery is fully charged before installation.

1. See Figure 1-8. With battery terminals facing outward, place battery in battery tray and install battery strap.

2. Insert fastener through battery positive cable terminal and into threaded hole of battery positive (+) terminal (5). Tighten fastener to 60-96

in-lbs

(6.8-10.9 Nm). Place

battery terminal cover over positive battery terminal.

3. Insert fastener through battery negative cable terminal into threaded hole of battery negative (–) terminal (4). Tighten fastener to 60-96

in-lbs

(6.8-10.9 Nm).

4. Apply a light coat of petroleum jelly or corrosion retardant material to both battery terminals.

5. Place slots on battery cover (2) on projections on battery tray (3). Install screw (1) to secure cover.

After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a)

6. Install seat.

2006 Dyna: Maintenance 1-13

Page 16

HOME

INSPECTION

1. Battery top must be clean and dry. Dirt and electrolyte on top of the battery can cause battery to self-discharge. Clean battery top with a solution of baking soda (sodium bicarbonate) and water (5 teaspoons baking soda per quart or liter of water). When the solution stops bubbling, rinse off the battery with clean water.

2. Clean cable connectors and battery terminals using a wire brush or sandpaper. Remove any oxidation.

3. Inspect the battery screws, clamps and cables for breakage, loose connections and corrosion. Clean clamps.

4. Check the battery posts for melting or damage caused by overtightening.

5. Inspect the battery for discoloration, raised top or a warped or distorted case, which might indicate that the battery has been frozen, overheated or overcharged.

6. Inspect the battery case for cracks or leaks.

STORAGE

11WARNING1WARNING

d0426x1x

Effect of temperature on

battery self-discharge rate

a c

i t

Months of stand

Figure 1-9. Battery Self-Discharge Rate

CAUTION

Do not allow battery to completely discharge. The electrolyte in a discharged battery will freeze. The more discharged a battery is, the more easily it can freeze and crack the battery case. (00218a)

If the motorcycle will not be operated for several months, such as during the winter season, remove the battery from the motorcycle and fully charge. See 8.12 BATTERY.

See Figure 1-9. Self-discharge is a normal condition and occurs continuously at a rate that depends on the ambient temperature and the battery’s state of charge. Batteries discharge at a faster rate at higher ambient temperatures. To reduce the self-discharge rate, store battery in a cool (not freezing), dry place.

Charge the battery every month if stored at temperatures below 60˚ F (16˚ C). Charge the battery more frequently if stored in a warm area above 60˚ F (16˚ C).

NOTES The GLOBAL BATTERY CHARGER (Part No. 99863-01A) may be used to maintain battery charge for extended periods of time without risk of overcharging or boiling.

When returning a battery to service after storage, refer to the instructions under 8.12 BATTERY.

1-14 2006 Dyna: Maintenance

Page 17

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d0678x1x

Fluid level should be

1/8-1/4 in. (3.2-6.4 mm) below

gasket surface

d0597x1x

Fluid level should be

1/8-1/4 in. (3.2-6.4 mm) below

gasket surface

BRAKES 1.6

FLUID INSPECTION

1CAUTION

Direct contact of D.O.T. 4 brake ﬂuid with eyes can cause irritation. Avoid eye contact. In case of eye contact ﬂush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake ﬂuid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a)

1. See Figure 1-10. Check level in rear brake master cylinder reservoir. Level should be 1/8-1/4 in. (3.2-6.4 mm) below the gasket surface.

CAUTION

Do NOT allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage. (00205b)

2. See Figure 1-11. Check level in front brake master cylinder reservoir. Level should be 1/8-1/4 in. (3.2-6.4 mm) below the gasket surface.

3. Install gaskets and covers. Tighten reservoir cover screws to 6-8

in-lbs

(0.7-0.9 Nm).

Figure 1-10. Rear Brake Master Cylinder Reservoir

11WARNING1WARNING

After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)

4. Front brake hand lever and rear brake foot pedal must have a ﬁrm feel when applied. If not, bleed system using only D.O.T. 4 BRAKE FLUID. See 1.7 BLEEDING

BRAKES.

Figure 1-11. Front Brake Master Cylinder Reservoir

2006 Dyna: Maintenance 1-15

Page 18

HOME

REAR PEDAL HEIGHT

The rear brake pedal should not require adjustment. If minor pedal height adjustment is desired:

1. See Figure 1-12. Brake rod (5) is threaded into push rod (3) in rear brake master cylinder (1), and locked in place with jam nut (4). Loosen jam nut.

11WARNING1WARNING

When adjusting brake control rod, never allow more than six threads to be exposed between control rod and jam nut. If more than six threads are exposed, brake rod can come apart resulting in loss of rear brake, which could cause death or serious injury. (00306a)

2. Using an open-end wrench on the push rod ﬂats, turn the push rod in the direction which will correct pedal height. When correct pedal height is obtained, tighten jam nut.

3. Verify that water drain hole in rubber boot (2), which covers rear brake push rod, is positioned to bottom.

NOTE Brake pedal freeplay is built into master cylinder and no adjustment is required. When pedal is pushed down with hand, a small amount of freeplay must be felt.

FXDWG model

d0431b1x

All models but FXDWG

1. Rear brake master cylinder

2. Rubber boot

3. Push rod

4. Jam nut

5. Brake rod

Figure 1-12. Rear Brake Pedal Height

1-16 2006 Dyna: Maintenance

Page 19

HOME

11WARNING1WARNING

7400

7425

BLEEDING BRAKES 1.7

GENERAL

1CAUTION

Front brake hand lever and rear brake foot pedal must have a ﬁrm feel when brakes are applied. If not, bleed system as described.

PROCEDURE

Figure 1-13. Front Brake Bleeder Valve

NOTE

Hydraulic brake ﬂuid bladder-type pressure equipment can be used to ﬁll brake master cylinder through the bleeder valve. Remove master cylinder reservoir cover so that system cannot pressurize. Do not use pressure bleeding equipment when the hydraulic system is sealed with master cylinder reservoir cover and gasket in place.

1. Remove bleeder valve cap. Install end of a length of clear plastic tubing over caliper bleeder valve; place other end in a clean container. Stand motorcycle upright.

a. Front brake bleeder valve-see Figure 1-13.

b. Rear brake bleeder valve-see Figure 1-14.

2. Add D.O.T. 4 BRAKE FLUID to master cylinder reservoir. Fluid level should be 1/8-1/4 in. (3.2-6.4 mm) below the gasket surface. Depress and hold brake lever/pedal to build up hydraulic pressure.

3. Open bleeder valve slowly about 1/2-turn counterclockwise; brake ﬂuid will ﬂow from bleeder valve and through tubing. When brake lever/pedal has moved its full range of travel, close bleeder valve (clockwise). Allow brake lever/pedal to return slowly to its released position.

Figure 1-14. Rear Brake Bleeder Valve

4. Repeat Steps 2-3 until all air bubbles are purged.

5. Tighten bleeder valve to 80-100 Install bleeder valve cap.

6. Verify master cylinder ﬂuid level as described in Step 2.

7. Attach covers to master cylinder reservoirs. Tighten screws on covers to 6-8

in-lbs

(9.0-11.3 Nm).

(0.7-0.9 Nm).

2006 Dyna: Maintenance 1-17

Page 20

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BRAKE PADS AND DISCS 1.8

INSPECTION

Check brake pads and discs:

●

At every scheduled service interval. Whenever the components are removed during service

●

procedures.

Brake Pads

11WARNING1WARNING

Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a)

See Figure 1-15. Replace brake pads (3) if brake pad friction material on either the front or rear caliper is worn to 0.04 in. (1.02 mm) or less above the backing plate (4). Always replace both pads in a caliper as a set. See BRAKE PAD REPLACE-

MENT below.

When checking the brake pads and discs, inspect the brake hoses for correct routing and any signs of damage.

Brake Disc Thickness

The minimum brake disc (2) thickness is stamped on the side of the disc. Replace disc if badly scored.

Brake Disc Lateral Runout and Warpage

Maximum brake disc lateral runout and warpage is 0.008 in. (0.2 mm) when measured near the outside diameter.

d0396x1x

1. Front brake caliper (viewed from below)

2. Brake disc

3. Brake pads

4. Backing plate

5. Rear brake caliper (viewed from above)

Figure 1-15. Brake Pad Inspection

1-18 2006 Dyna: Maintenance

Page 21

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7425

d0558a2x

1. Two tabs on backing plate

2. Single square tab on backing plate

3. Curved portion

BRAKE PAD REPLACEMENT

Rear Brake Caliper

1. If present, remove right saddlebag.

2. Remove the rear master cylinder reservoir cap. As the pistons are pushed back into the caliper, ﬂuid level may rise more than 1/8 in. (3.2 mm). You may have to remove ﬂuid to allow for this.

3. See Figure 1-16. Loosen, but do not remove, both pad pins (12 pt/0.25 in.).

4. Pry the inside pad back. Use steady pressure to prevent scoring the brake disc. Pry between the pad and the brake disc in order to push the caliper pistons back into their bores.

NOTE Do not completely pull pad pins from caliper during the next step. Completely removing pad pins at this time will cause difﬁculty during assembly.

5. Once the pistons have been fully retracted into their

bores, pull pad pins part way until the inside pads drop free. Note the pad’s original orientation for replacement purposes.

NOTE See Figure 1-17. The front left, front right (not present on all vehicles) and rear brake calipers use the same exact brake pad set. Install pad with two tabs (1) on the inboard side of the rear caliper.

6. Install

7. Install pad pins until the pins snap into place with an

8. Pump brake pedal lever to move inside pistons out until

9. Pry the outside pad back. Pry between the pad and the

10. Verify that inside pads are captured between brake disc

new

inside brake pad using the same orientation as the pad previously removed. Curved portion of pad must face rear of motorcycle.

audible click. Do not fully tighten at this time.

they contact inside brake pads.

brake disc in order to push the caliper pistons back into their bores.

and pistons. Completely remove pad pins to free outside brake pad. Note the pad’s original orientation for replacement purposes.

Figure 1-16. Pad Retaining Pins

(Rear Caliper Shown)

Figure 1-17. Brake Pad Orientation

2006 Dyna: Maintenance 1-19

Page 22

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11. Inspect pad pins for grooving and wear. Measure the pad pin diameter in an unworn area, and then in the area of any grooving or wear. If wear is more than 0.015 in. (0.38 mm), replace both pins.

12. Install

13. Install both pad pins through holes in inner and outer

new

outside brake pad using the same orientation as the pad previously removed. If the inside pad moved during the previous step, reinstall. Curved portion of pad must face rear of motorcycle.

brake pads. Tighten to 180-200

in-lbs

(20.3-22.6 Nm).

11WARNING1WARNING

After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufﬁcient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a)

14. Pump brake pedal to move pistons out until they contact both brake pads. Verify piston location against pads.

15. Check brake ﬂuid level in master cylinder. Fill to proper level if necessary using D.O.T. 4 BRAKE FLUID. Install master cylinder reservoir cap. Tighten reservoir cap screws to 6-8

16. Install right saddlebag if necessary.

in-lbs

(0.7-0.9 Nm).

7400

1. Short mounting bolt (12 pt/10 mm)

2. Long mounting bolt (12 pt/10 mm)

3. Pad pins (12 pt/0.25 in)

Figure 1-18. Front Brake Caliper

(Left Side Shown)

11WARNING1WARNING

17. Test brake system. a. Turn ignition switch ON. Pump brake pedal to verify

operation of the brake lamp.

b. Test ride the motorcycle. If the brakes feel spongy,

bleed the system. See 1.7 BLEEDING BRAKES.

NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km). This allows the discs.

new

pads to become conditioned to the brake

1-20 2006 Dyna: Maintenance

Page 23

HOME

12206

1. Cast in spacer

2. Rear axle cap fastener

3. Front axle cap fastener

4. gap

Front Brake Caliper

1. Remove the front master cylinder reservoir cap. As the pistons are pushed back into the caliper, ﬂuid level may rise more than 1/8 in. (3.2 mm). You may have to remove ﬂuid to allow for this.

2. See Figure 1-18. Loosen, but do not remove, both pad pins (3) (12 pt/0.25 in.).

3. Remove both caliper mounting bolts (1, 2) (metric). Detach caliper from front forks and brake disc.

4. Pry the pads back to force all four caliper pistons into their bores.

5. With the pistons retracted, remove the pad pins and brake pads.

6. Inspect pad pins for grooving and wear. Measure the pad pin diameter in an unworn area, and then in the area of any grooving or wear. If wear is more than 0.015 in. (0.38 mm), replace both pins.

NOTES

See Figure 1-17. The front and rear brake calipers use

●

the same exact brake pad set.

The pad with two tabs (1), installs on the outboard side of

●

the caliper.

Figure 1-19. Axle cap

7. Install

8. Loosely install the pad pins until you hear an audible

9. Attach caliper to front fork.

new

pads into caliper. Curved portion of pad must

face rear of motorcycle.

click.

a. See Figure 1-18. Place caliper over brake disc with

bleeder valve facing upwards.

b. Loosely install long mounting bolt (2) (12 pt/10 mm)

into top hole on fork leg.

c. Install short mounting bolt (1) (12 pt/10 mm) into

bottom hole on fork leg. Tighten bottom mounting bolt to 28-38 ft-lbs (38.0-51.5 Nm).

d. Final tighten the top mounting bolt to 28-38 ft-lbs

(38.0-51.5 Nm).

e. Final tighten both pad pins to 180-200

22.6 Nm).

f. See Figure 1-19. With cast in spacer (1) of axle cap

facing rear of vehicle, tighten rear axle cap fastener (2) to 12 ft-lbs (16.3 Nm) while holding slider against 7/16 drill bit if necessary.

g. While holding slider against 7/16 drill bit if neces-

sary, tighten front axle cap fastener to 12 ft-lbs (16.3 Nm). Remove drill bit.

in-lbs

(20.3-

2006 Dyna: Maintenance 1-21

Page 24

HOME

11WARNING1WARNING

10. Pump brake hand lever to move pistons out until they contact both brake pads. Verify piston location against pads. If the front wheel is off the ground, rotate wheel to check for excessive brake pad drag.

11. Check brake ﬂuid level in master cylinder. Fill to proper level if necessary using D.O.T. 4 BRAKE FLUID. Install master cylinder reservoir cap. Tighten reservoir cap screws to 6-8

in-lbs

(0.7-0.9 Nm).

11WARNING1WARNING

12. Test brake system. a. Turn ignition switch ON. Pump brake hand lever to

verify operation of the brake lamp.

b. Test ride the motorcycle. If the brakes feel spongy,

bleed the system. See 1.7 BLEEDING BRAKES.

NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km). This allows the discs.

new

pads to become conditioned to the brake

1-22 2006 Dyna: Maintenance

Page 25

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o0250x0x

o0249x0x

Sidewall

Tread

surface

TIRES AND WHEELS 1.9

TIRES

11WARNING1WARNING

Match tires, tubes, air valves and caps to the correct wheel rim. Contact a Harley-Davidson dealer. Mismatching can result in damage to the tire bead, allow tire slippage on the rim or cause tire failure, which could result in death or serious injury. (00023a)

Use only Harley-Davidson approved tires. Using non-

●

approved tires can adversely affect stability, which could result in death or serious injury. (00024a)

Use inner tubes on laced (wire spoked) wheels.

●

Using tubeless tires on laced wheels can cause air leaks, which could result in death or serious injury. (00025a)

●

Inner tubes must not be used in radial tires and radial tires must not be used on laced (wire spoked) wheels.

●

Tubeless tires are used on all Harley-Davidson cast and disc wheels.

●

Tire sizes are molded on the tire sidewall. Inner tube sizes are printed on the tube.

TIRE REPLACEMENT

See Figure 1-20. Tread wear indicator bars appear on tire tread surfaces when 1/32 inch (0.8 mm) or less tire tread remains. Arrows on tire sidewalls pinpoint location of wear bar indicators. Always remove tires from service before they reach the tread wear indicator bars, indicating 1/32 inch (0.8 mm) tread pattern depth remaining.

New tires are needed if any of the following conditions exist.

● Tire wear indicator bars become visible on the tread sur-

faces.

● Tire cords or fabric become visible through cracked side-

walls, snags or deep cuts.

● A bump, bulge or split in the tire is found.

● Puncture, cut or other damage to the tire that cannot be

repaired.

Check tire pressure and tread:

●

As part of the pre-ride inspection.

●

At every scheduled service interval.

1. Inspect each tire for punctures, cuts, and breaks.

2. Inspect each tire for wear. Replace tires before they reach the tread wear indicator bars.

NOTE

Missing indicator wear bars represent less than 1/32 in. (0.8 mm) tread pattern depth remaining.

11WARNING1WARNING

Do not inﬂate tire beyond maximum pressure as speciﬁed on sidewall. Over inﬂated tires can blow out, which could result in death or serious injury. (00027a)

3. Check for proper front and rear tire pressures when tires are cold. Compare results against Tab le 1-5.

Table 1-5. Tire Pressures

ALL MODELS

DUNLOP TIRES

ONLY

SOLO RIDER

PSI kPA PSI kPA

RIDER & ONE

PASSENGER

Figure 1-20. Tread Wear Indicators

Front 30 207 30 207

Rear 36 248 40 276

2006 Dyna: Maintenance 1-23

Page 26

HOME

WHEEL BEARINGS

Service wheel bearings:

● Inspect any time the wheels are removed.

● Replace when bearings exceed end play service wear

limit of 0.002 in. (0.051 mm).

Check wheel bearings and axle spacers for wear and corrosion. Excessive play or roughness indicates worn bearings. Replace bearings in sets only. See 2.6 SEALED WHEEL

BEARINGS.

WHEEL SPOKES

1. Raise motorcycle wheel off the ground.

11WARNING1WARNING

Spokes that are too tight can draw nipples through the rim or distort hub ﬂanges. Spokes that are too loose can continue to loosen when put in service. Either condition can adversely affect stability and handling, which could result in death or serious injury. (00286a)

CAUTION

If nipples require more than one full turn to tighten spoke, remove tire to check that spoke is not protruding far enough to damage tube.

2. Lightly tap each spoke with a spoke wrench. Loose spokes will sound dull and must be tightened. Tighten spokes to 55-65 in-lbs (6.2-7.3 Nm). If more than a few spokes are loose, true the entire wheel following procedure under 2.10 TRUING LACED WHEEL.

1-24 2006 Dyna: Maintenance

Page 27

HOME

PRIMARY CHAIN 1.10

GENERAL

NOTE The 2006 Dyna models have an automatic chain tensioner. See 6.3 DRIVE COMPONENTS for primary chain procedures.

2006 Dyna: Maintenance 1-25

Page 28

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PRIMARY CHAINCASE LUBRICANT 1.11

CHANGING LUBRICANT

1. See Figure 1-21. Remove drain plug at bottom of inner primary chaincase. Drain lubricant into suitable container.

2. Clean drain plug. If plug has accumulated a lot of debris, inspect the condition of chaincase components.

3. Install new o-ring on drain plug.

4. Install drain plug back into primary chaincase cover. Tighten plug to 36-60 in-lbs (4.1-6.8 Nm).

5. See Figure 1-22. Remove ﬁve TORX screws with captive washers (1) to detach clutch inspection cover (2) from primary chaincase cover.

6. Remove the gasket. Wipe oil from groove in chaincase cover and mounting surface.

11WARNING1WARNING

Check that no lubricant gets on rear tire, wheel or brakes when changing ﬂuid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047a)

12207

Figure 1-21. Removing Chaincase Drain Plug

d0161b1x

CAUTION

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

7. See Figure 1-22. Pour 32 oz (0.95 liter) of primary chain- case lubricant in through the clutch inspection cover opening.

NOTE

● Use only genuine Harley-Davidson FORMULA+ TRANS-

MISSION AND PRIMARY CHAINCASE LUBRICANT, Part No. 99851-05 (quart).

● If new clutch discs are being installed, or if the lubricant

has been wiped from serviceable discs, submerge the discs in FORMULA+ PRIMARY CHAINCASE LUBRICANT for a minimum of ﬁve minutes before installation.

1. TORX screw with captive washer (5)

2. Clutch inspection cover

3. Seal

Figure 1-22. Clutch Cover

1-26 2006 Dyna: Maintenance

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d0161c1x

8. Install clutch inspection cover and seal as follows: a. Thoroughly wipe all lubricant from cover mounting

surface and groove in chaincase.

b. See Figure 1-22. Position seal (3) in groove in pri-

mary chaincase cover and press each of the nubs on seal into the groove. The nubs will retain seal in position.

c. See Figure 1-23. Insert screw (with captive washer)

through clutch inspection cover and carefully thread it into the top cover screw hole.

d. Start the remaining four screws (with captive wash-

ers).

e. Alternately tighten screws to 84-108 in-lbs (9.5-12.2

Nm) following torque sequence shown in Figure 1-

23.

Figure 1-23. Clutch Cover Torque Sequence

2006 Dyna: Maintenance 1-27

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CLUTCH 1.12

ADJUSTMENT

CAUTION

Perform the clutch adjustment with the motorcycle at room temperature. The clearance at the adjuster screw will increase as the powertrain temperature increases. If adjuster screw is adjusted with powertrain hot, clearance at push rod bearing could be insufﬁcient with powertrain cold and clutch slippage could occur.

1. Stand motorcycle upright and level.

2. Remove ﬁve TORX screws with captive washers to detach clutch inspection cover from primary chaincase cover.

3. Remove and discard clutch inspection cover seal.

4. See Figure 1-24. Add freeplay to cable.

a. Slide rubber boot (1) off cable adjuster.

b. Holding cable adjuster (2) with 1/2 in. wrench,

loosen jam nut (3) using a 9/16 in. wrench.

d0599x1x

1. Rubber boot

2. Cable adjuster

3. Jam nut

4. Cable end

Figure 1-24. Clutch Cable Adjuster

1. Locknut

2. Clutch adjuster screw

c. Turn cable adjuster (2) until there is a large amount

of freeplay at clutch hand lever.

5. See Figure 1-25. Loosen locknut (1) on clutch adjuster screw (2). To take up all freeplay, turn screw inward (clockwise) until lightly seated. Activate the clutch lever to verify the balls are seated in the ramps.

6. Back out adjusting screw (counterclockwise) 1/2 to 1 full turn. Tighten jam nut to 72-120 in-lbs (8.1-13.6 Nm), while holding adjusting screw with an Allen wrench.

7. Squeeze clutch lever to maximum limit three times, to set ball and ramp release mechanism.

8. Check freeplay.

a. Turn cable adjuster away from jam nut until slack is

eliminated at hand lever.

b. See Figure 1-26. Pull clutch cable ferrule (2) away

from clutch lever bracket (3) to check freeplay. Turn cable adjuster as necessary to obtain 1/16-1/8 in. (1.6-3.2 mm) freeplay between end of cable ferrule and clutch lever bracket.

9. Hold adjuster with 1/2 in. wrench. Using 9/16 in. wrench, tighten jam nut against cable adjuster. Cover cable adjuster mechanism with rubber boot.

Figure 1-25. Clutch Adjuster Screw

d0382a1x

1. Clutch cable

2. Cable ferrule

3. Clutch lever bracket

1/16-1/8 in. (1.6-3.2 mm)

d0383c1x

1-28 2006 Dyna: Maintenance

Figure 1-26. Clutch Hand Lever

Page 31

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10. Install clutch inspection cover and seal. Install seal as follows:

a. Thoroughly wipe all lubricant from cover mounting

surface and groove in chaincase.

b. See Figure 1-22. Position seal (3) in groove in pri-

mary chaincase cover and press each of the nubs on seal into the groove. The nubs will retain seal in position.

c. See Figure 1-23. Insert screw (with captive washer)

through clutch inspection cover and carefully thread it into the top cover screw hole.

d. Start the remaining four screws (with captive wash-

ers).

e. Alternately tighten screws to 84-108 in-lbs (9.5-12.2

Nm) following torque sequence shown in Figure 1-

23.

2006 Dyna: Maintenance 1-29

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TRANSMISSION LUBRICANT 1.13

CHANGING LUBRICANT

11767

1. See Figure 1-27. Remove transmission ﬁller plug.

2. See Figure 1-28. Remove transmission drain plug (2) and drain lubricant into a suitable container.

CAUTION

Do not over-tighten drain plug. Doing so could result in a lubricant leak. (00200a)

3. Install drain plug. a. Inspect O-ring on drain plug for tears or damage.

Replace as required. Wipe any foreign material from plug.

b. Install O-ring and drain plug. Tighten to 14-21 ft-lbs

(19.0-28.5 Nm). Do not over-tighten.

11WARNING1WARNING

4. Fill the transmission with 32 oz. (0.95 liter) of GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT, Part No. 99851-05 (quart).

5. Check the transmission lubricant level with engine turned off and motorcycle resting on jiffy stand on level surface.

6. See Figure 1-27. Unscrew and remove transmission lubricant ﬁller cap with attached dipstick. Wipe dipstick clean.

7. See Figure 1-29. Reinsert dipstick into transmission ﬁll hole. Bottom edge of threaded section of dipstick should rest on lip of ﬁll hole. Do not screw ﬁller cap in.

8. Remove ﬁller cap and check lubricant level on dipstick. If necessary, add lubricant and recheck until level is between lower mark (1) and upper mark (2) on dipstick.

9. Install ﬁller plug/dipstick and tighten to 25-75 in-lbs (2.8-

8.5 Nm).

Figure 1-27. Transmission Lubricant Filler Plug/Dipstick

Front of motorcycle

d0442x3x

1. Engine oil drain plug

2. Transmission drain plug and o-ring @ 14-21 ft-lbs (19.0-28.5 Nm)

Figure 1-28. Oil Pan

11766

1-30 2006 Dyna: Maintenance

1. Lower mark (add lubricant)

2. Upper mark (full)

3. Bottom edge of threaded section

Figure 1-29. Filler Plug/Dipstick

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1. Belt tension gauge

2. Belt cradle

3. 0 ft-lbs (0 kg) mark

4. O-ring

5. 10 lbs (4.5 kg) mark

6. Knob

d0600a1x

d0164x1x

10 lbs (4.5 kg)

of force

5/16-3/8 in.

(7.9-9.5 mm)

8844

1. Debris deﬂector

2. Belt deﬂection viewing window

3. Drive belt deﬂection graduations

4. Drive belt

REAR BELT DEFLECTION 1.14

INSPECTION

PART NO. SPECIALTY TOOL

HD-35381 Belt tension gauge

Check rear belt deﬂection:

● As part of the pre-ride inspection.

● At every scheduled service interval.

When checking belt deﬂection:

● Set belt tension at tightest point in belt.

● Measure belt deﬂection with motorcycle cold and the

approximate weight of the owner on motorcycle.

1. See Figure 1-30. Obtain BELT TENSION GAUGE (HD-

35381).

NOTE Customers may purchase gauge from an authorized HarleyDavidson dealer.

2. To use the belt tension gauge:

a. Slide O-ring (4) toward 0 lbs (0 kg) mark (3). b. Fit belt cradle (2) against bottom of drive belt half-

way between drive pulleys (point A in Figure 1-31.).

c. Press upward on knob (6) until O-ring slides down to

10 lbs (4.5 kg) mark (5).

d. See Figure 1-32. Measure belt deﬂection as viewed

through deﬂection viewing window (2) while holding gauge steady. Deﬂection graduations (3) are 1/8 in. (3.2 mm) apart.

Figure 1-30. Belt Tension Gauge (Part No. HD-35381)

Figure 1-31. Checking Belt Deﬂection

Figure 1-32. Belt Deﬂection Window

2006 Dyna: Maintenance 1-31

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3. See Figure 1-31. Check that the drive belt bottom strand deﬂects 5/16-3/8 in. (7.9-9.5 mm) while applying 10 lbs (4.5 kg) of force upward at point A.

4. Measure belt deﬂection several times, each time with belt moved (by rotating rear wheel) to a different position on sprockets.

NOTE Do not rely on “feel” for the proper deﬂection as this typically results in belts which are under tensioned. Always use H-D BELT TENSION GAUGE (Part No. HD-35381) to determine the 10 lb. (4.5 Kg) deﬂection force. Loose belts will fail due to “ratcheting” (jumping a tooth) with resultant tensile cord crimping and breakage.

ADJUSTMENT

If belt adjustment is necessary, perform the following procedure:

1. See Figure 1-33. Remove spring clip (1) and loosen axle

nut (2).

2. Adjust belt tension by turning the axle adjusters (3) an

equal number of turns to keep the wheel aligned until the speciﬁcation in step 3 under ADJUSTMENT above is achieved.

3. Verify rear wheel alignment. See 2.13 VEHICLE ALIGN-

MENT.

11WARNING1WARNING

Check wheel bearing end play after tightening axle nut to speciﬁed torque. Excessive end play can adversely affect stability and handling. Insufﬁcient end play can cause bearing seizure. Either condition can cause loss of control, which could result in death or serious injury. (00285a)

4. Tighten axle nut (2) to 60 ft-lbs (81.3 Nm).

5. Check to see if the spring clip (1) can be installed. If

required, tighten nut just enough to align axle hole and nut slots, but do not exceed 65 ft-lbs (88.1 Nm).

1. Axle adjuster

2. Axle nut and spring clip

Figure 1-33. Axle Adjusters

1-32 2006 Dyna: Maintenance

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1. Tooth

2. Groove

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REAR BELT AND SPROCKETS 1.15

GENERAL

NOTE

When a drive belt is replaced for any reason other than stone damage, it is recommended that the transmission and rear sprockets also be replaced to increase the longevity of the new drive belt. In the case of stone damage, inspect sprockets for damage and replace as required.

CLEANING

Keep dirt, grease, oil, and debris off the belt and sprockets. Clean the belt with a rag which is slightly damp with a light cleaning agent.

INSPECTION

Sprockets

NOTE

If chrome chips or gouges to rear sprocket are large enough to be harmful, they will leave a pattern on the belt face.

1. See Figure 1-34. Inspect each tooth (1) of rear sprocket for:

a. Major tooth damage.

b. Large chrome chips with sharp edges.

c. Gouges caused by hard objects.

d. Excessive loss of chrome plating (see step 2).

2. To check if chrome plating has worn off, drag a scribe or sharp knife point across the bottom of a groove (2) (between two teeth) with medium pressure.

a. If scribe or knife point slides across groove without

digging in or leaving a visible mark, chrome plating is still good.

b. If scribe or knife points digs in and leaves a visible

mark, it is cutting the bare aluminum. A knife point will not penetrate the chrome plating.

3. Replace rear sprocket if major tooth damage or loss of chrome exists.

Figure 1-34. Rear Sprocket

Rear Belt

See Figure 1-35. Inspect drive belt for:

● Cuts or unusual wear patterns.

● Outside edge bevelling (8). Some bevelling is common,

but it indicates that sprockets are misaligned.

● Outside ribbed surface for signs of stone puncture (7). If

cracks/damage exists near edge of belt, replace belt immediately. Damage to center of belt will require belt replacement eventually, but when cracks extend to edge of belt, belt failure is imminent.

● Inside (toothed portion) of belt for exposed tensile cords

(normally covered by nylon layer and polyethylene layer). This condition will result in belt failure and indicates worn transmission sprocket teeth. Replace belt and transmission sprocket.

● Signs of puncture or cracking at the base of the belt

teeth. Replace belt if either condition exists.

● Replace belt if conditions 2, 3, 6 or 7 (on edge of belt)

exist.

NOTE Condition 1 may develop into 2 or 3 over time. Condition 1 is not grounds for replacing the belt, but it should be watched closely before condition 2 develops which will require belt replacement.

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1 2

3 4

5 6

Stone

Cross-section shown

7 8

Figure 1-35. Drive Belt Wear Patterns

Table 1-6. Drive Belt Wear Analysis

PATTERN CONDITION REQUIRED ACTION

1 Internal tooth cracks (hairline) OK to run, but monitor condition

2 External tooth cracks Replace belt

3 Missing teeth Replace belt

4 Chipping (not serious) OK to run, but monitor condition

Sprocket side of belt

5 Fuzzy edge cord OK to run, but monitor condition

6 Hook wear Replace belt

7 Stone damage Replace belt if damage is on the edge

8Bevel wear (outboard edge only) OK to run, but monitor condition

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3587

SUSPENSION ADJUSTMENTS 1.16

ALL MODELS

The rear shock absorber springs can be adjusted to ﬁve positions to compensate for various loads.

● For heavy loads, the springs should be compressed.

● For lighter loads the springs should be extended.

See Figure 1-36. To adjust the rear shock absorber, turn spring adjusting cam to desired position with spanner wrench. Both spring adjusting cams must be adjusted to the same position. When returning to off-cam position, cams should be backed off in opposite direction.

Figure 1-36. Rear Shock Absorber Spring Adjustment

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STEERING HEAD BEARINGS 1.17

ADJUSTMENT

Bearing Adjustment (Fall-Away)

1. Support motorcycle in an upright position so the front end is completely suspended and the vehicle is level.

2. Remove all accessory weight, such as a windshield, that may inﬂuence the way the front end swings. If clutch cable is routed so it pulls the front end one way or the other, disconnect it.

3. Place a suitable marking material, such as masking tape, over the fender tip.

4. Install a pointer so the base is stationary on the ﬂoor and the pointer indicates the center of the fender. The front end should be straight ahead, however the balance point may be slightly off center.

5. Check steering head bearing tension. a. Tap the fender on one side until the front end begins

to “fall-away” by itself. Label this point on the mark-

ing material. b. Repeat the previous step in the other direction. c. Measure distance between marks.

6. The distance between the “fall-away” marks must be 2.0-

4.0 in. (50.8-101.6 mm).

NOTE If distance measured is 2.0-4.0 in. (50.8-101.6 mm) no bearing adjustment is needed.

NOTE If distance measured is outside the range given in step 7 bearing adjustment is needed. See Figure 1-37. To access the adjuster nut (1) the upper triple clamp (2) must be moved upward.

7. With HUBCAP REMOVER AND INSTALLER (HD-

41494) unscrew and remove stem cap (3).

8. Bend down the fork stem lock washer (4) tab, and loosen

fork stem nut (5).

9. Loosen upper triple clamp pinch bolts and move upper

triple clamp up enough to expose star nut

10. Tighten one pinch bolt enough to hold upper triple clamp

in the raised position.

1. Star nut

2. Upper triple clamp

3. Stem cap

4. Lock washer

5. Stem nut

Figure 1-37. Steering Head Components

11. Tighten or loosen the fork adjuster nut until the measurement is within limits.

a. If the distance is more than 4.0 in. (101.6 mm), turn

the adjuster nut counter clockwise to loosen.

b. If the distance is less than 2.0 in. (50.8 mm), turn the

adjuster nut clockwise to tighten.

12. Lower upper triple clamp and tighten stem nut to 45-55 ft-lbs.

13. Check fall-away. If it is 2.0-4.0 in. (50.8-101.6 mm), tighten upper triple clamp pinch bolts to 30-35 ft-lbs (40.7-47.5 Nm).

14. Repeat the “fall-away” procedure to be sure the adjustment is correct.

15. Bend lock tab on lock washer against stem nut and install stem cap.

16. Install and adjust clutch cable.

17. Test ride motorcycle.

6. Pinch bolt (2)

1-36 2006 Dyna: Maintenance

LUBRICATION

Use SPECIAL PURPOSE GREASE (Part No. 99857-97) every 30,000 mile (48,280 km) service interval. See 2.19

STEERING HEAD for steering head bearing lubrication.

Page 39

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FRONT FORK OIL 1.18

REPLACING FORK OIL

NOTE Fork assemblies must be removed to drain fork oil. See 2.18

FRONT FORK.

2006 Dyna: Maintenance 1-37

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SPARK PLUGS 1.19

INSPECTION

1. After the engine has cooled to room temperature, disconnect cables from both spark plugs.

2. Remove spark plugs. If a plug has eroded electrodes, heavy deposits or a cracked insulator, discard it.

3. See Figure 1-38. Compare your observations of the plug deposits with the descriptions provided below.

a. A wet, black and shiny deposit on plug base, elec-

trodes and ceramic insulator tip indicates an oil fouled plug. The condition may be caused by one or more of the following: worn pistons, worn piston rings, worn valves, worn valve guides, worn valve seals, a weak battery or a faulty ignition system.

b. A dry, ﬂuffy or sooty black deposit indicates an air-

fuel mixture that is too rich, engine idling for excessive periods of time.

c. A light brown, glassy deposit indicates an over-

heated plug. This condition may be accompanied by cracks in the insulator or by erosion of the electrodes and is caused by an air-fuel mixture that is too lean, a hot-running engine, valves not seating or improper ignition timing. The glassy deposit on the spark plug is a conductor when hot and may cause high-speed misﬁring. A plug with eroded electrodes, heavy deposits or a cracked insulator must be replaced.

d. A plug with a white, yellow, tan or rusty brown pow-

dery deposit indicates balanced combustion. Clean off spark plug deposits at regular intervals.

4. If the plugs require cleaning between tune-ups, proceed as follows:

a. Degrease ﬁring end of spark plug using ELECTRI-

CAL CONTACT CLEANER. Dry plug with compressed air.

b. Use a thin ﬁle to ﬂatten spark plug electrodes. A

spark plug with sharp edges on its electrodes requires 25-40% less ﬁring voltage than one with rounded edges.

c. If the plugs cannot be cleaned, replace with No.

6R12 spark plugs.

4636

Figure 1-38. Typical Spark Plug Deposits

gauge is felt when passing it between electrodes. Proper gap measurement is 0.038-0.043 in. (0.97-1.09 mm).

6. Check condition of threads on cylinder head and plug. If necessary to remove deposits, apply penetrating oil and clean out with a thread chaser.

7. Apply LOCTITE ANTI-SEIZE to plugs. Install and tighten to 12-18 ft-lbs (16.3-24.4 Nm).

8. Connect spark plug cables. Rear cylinder plug cable attaches to top coil terminal. Verify that cables are securely connected to coil and spark plugs.

5. Check electrode gap with a wire-type feeler gauge. Bend the outside of the electrode so only a slight drag on the

1-38 2006 Dyna: Maintenance

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AIR CLEANER FILTER 1.20

REMOVAL

1. See Figure 1-39. Remove screw (1) and air cleaner cover (2).

2. Remove three TORX screws (3) and bracket (4) from ﬁlter element (5).

3. Gently pull both rubber breather tubes (8) from the back of the element. Remove ﬁlter element and gasket (6).

4. Replace the ﬁlter element if damaged or if ﬁlter media cannot be adequately cleaned.

11WARNING1WARNING

Do not use gasoline or solvents to clean ﬁlter element. Flammable cleaning agents can cause an intake system ﬁre, which could result in death or serious injury. (00101a)

5. Gently pull the breather tubes from the breather bolts on the backplate.

11WARNING1WARNING

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

6. Clean ﬁlter element. a. Wash the paper/wire mesh air ﬁlter element and

breather tubes in lukewarm water with a mild detergent. Do not strike ﬁlter element on a hard surface to dislodge dirt.

b. Allow ﬁlter to either air dry or blow it dry, from the

inside, with low pressure air. Do NOT use air cleaner ﬁlter oil on the Harley-Davidson paper/wire mesh air ﬁlter element.

c. Hold the ﬁlter element up to a strong light source. If

light is uniformly visible through the element, it is sufﬁciently clean.

7. Inspect seal ring on cover for cracks or tears. Verify that it seals tightly to backplate. Replace as required.

d0089x1x

1. Screw @ 36-60 in-lbs (4.1-6.8 Nm)

2. Air cleaner cover

3. T27 TORX screw (3) @ 20-40 in-lbs (2.3-4.5 Nm)

4. Bracket

5. Filter element

6. Gasket

7. Backplate

8. Breather hose (2)

Figure 1-39. Air Cleaner Assembly

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8. Inspect breather tubes for tears, cuts, holes or other damage. Replace as necessary.

NOTE The breather tubes allow crankcase vapors to be directed into the air ﬁlter element. By providing effective recirculation of crankcase vapor, the tubes serve to eliminate the pollutants normally discharged from the crankcase. Air cleaner mounting without installation of the breather tubes, or with breather tubes that are not air tight, allows crankcase vapors to be vented into the atmosphere in violation of legal emissions standards. This will also negatively affect the engine’s breather system as it will cause the umbrella valve to ﬂutter.

9. Wipe inside of air cleaner cover and backplate with damp

cloth to remove dust.

10. On California models only, make sure trap door swings

freely.

INSTALLATION

1. See Figure 1-40. Position new gasket on backplate.

2. See Figure 1-41. Insert two breather tubes into the holes

in back of the ﬁlter element and place the element back into position. Attach breather tubes to breather screws on backplate.

3. See Figure 1-39. Install air ﬁlter element and bracket.

a. Make sure gasket holes are aligned with backplate

holes.

b. Use three TORX screws (3) to secure bracket and

ﬁlter element. Tighten to 20-40 in-lbs (2.3-4.5 Nm).

4. Install air ﬁlter cover (2).

a. Apply a drop of LOCTITE THREADLOCKER 243

(blue) to threads of air cleaner cover screw (1).

b. Install air cleaner cover using screw. Tighten to 36-

60 in-lbs (4.1-6.8 Nm).

7429a

Gasket

Figure 1-40. Gasket Installation

7430

Figure 1-41. Breather Hose Holes on Backside of Filter

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CABLE AND CHASSIS LUBRICATION 1.21

GENERAL

Inspect and lubricate the front brake lever, clutch hand lever, throttle control cables, clutch cable, foot shift lever, rear brake lever bearings and jiffy stand.

CABLES AND HAND LEVERS

See 1.22 THROTTLE CABLES for throttle cables. Use SUPER OIL (Part No. HD-94968-85TV) for hand levers

and cables.

JIFFY STAND

Clean and lubricate the jiffy stand. If service is on muddy or dusty roads, clean and lubricate at

shorter intervals. See 2.28 JIFFY STAND for more informa- tion.

2006 Dyna: Maintenance 1-41

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THROTTLE CABLES 1.22

CABLE INSPECTION, LUBRICATION AND ADJUSTMENT

Inspection and Lubrication

1. See Figure 1-42. Remove two screws (1) to separate the

upper handlebar housing from the lower housing.

2. Unhook each ferrule and cable from the throttle grip and

remove the throttle sleeve.

3. Apply a light coat of graphite to the handlebar and

replace throttle grip.

4. Put one or two drops of SUPER OIL (Part No. 94968-

85TV) into the housing of each cable.

5. When assembling the handlebar housing, tighten both

screws (1) to 35-45 in-lbs (4.0-5.1 Nm).

Adjustment

The throttle control must operate freely without binding. With the throttle friction adjustment screw backed off, the throttle grip must freely return to the closed (idle) position. The throttle control also must open and close freely when the front wheel is turned to both the right and left fork stops. If the throttle grip does not return to the idle position freely, check the throttle friction adjustment screw tension. If the adjuster screw is backed off, inspect the cables for short bends.

d0419x1x

1. Screws (2)

2. Throttle cable adjuster

3. Jam nuts (2)

4. Idle cable adjuster

Figure 1-42. Throttle Cable Adjusters

11WARNING1WARNING

Do not tighten throttle friction adjustment screw to the point where the engine will not return to idle automatically. Over-tightening can lead to loss of vehicle control, which could result in death or serious injury. (00031b)

1. Slide rubber boot off throttle cable adjuster mechanism.

See Figure 1-42. Holding cable adjuster with a 3/8 inch wrench, loosen jam nut turning in a clockwise direction. Back jam nut away from cable adjuster until it stops. Turn cable adjuster clockwise until it contacts jam nut. Repeat procedure on idle cable adjuster.

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1. Throttle cable

2. Throttle cam

3. Idle cable

4. Idle cable housing

5. Cam stop

6. Spring

d0796x1x

2. Point the front wheel straight ahead. Gently turn the throttle grip so that the throttle is wide open (fully counterclockwise) and then hold in position. Now turn the cable adjuster counterclockwise until the throttle cam (2) just touches the cam stop (5) on the induction module. See Figure 1-43. Release the throttle grip, turn cable adjuster counterclockwise an additional 1/2-1 full turn, and then tighten the jam nut against the cable adjuster. Cover cable adjuster mechanism with rubber boot.

3. Turn the front wheel full right. Turn the idle cable adjuster counterclockwise until the cable housing (4) just touches the spring (6) in the cable guide (as seen through slot). Work the throttle grip to verify that the throttle cable returns to the idle position when released. If the cable does not return to idle, turn the cable adjuster clockwise slightly until the correct response is achieved. Tighten jam nut against the cable adjuster and cover cable adjuster mechanism with rubber boot.

Figure 1-43. Induction Module Cable Connection

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ENGINE MOUNTS 1.23

INSPECTION

1. See Figure 1-44. Check for cracks or tears in the mount rubber.

2. Check stabilizer links for wear.

3. Check that all engine mount bolts are tight.

4. Check that all engine mount rivets are not sheared.

5. Check that the mounts are supporting the weight of the motor.

d0738x1x

1. Rear isolator

2. Front isolator

3. Front engine mount bracket

4. Top engine mount bracket

5. Top stabilizer mount

Figure 1-44. Engine Mounts

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25 ft

(7.6 m)

d0110x1x

35 in. (0.9 m)

d0417x1x

HEADLAMP ALIGNMENT 1.24

INSPECTION

11WARNING1WARNING

The automatic-on headlamp feature provides increased visibility for riders. Be sure headlamp is on at all times. Low visibility of rider can result in death or serious injury. (00030a)

Check headlamp for proper height and lateral alignment:

● When the new owner takes delivery of the motorcycle.

● When there is a change in load (adding luggage, etc.)

1. Verify correct front and rear tire pressure. See 1.9 TIRES

AND WHEELS.

2. Place motorcycle on level ﬂoor (or pavement) in an area with minimum light.

3. See Figure 1-45. Position motorcycle 25 ft (7.6 m) away from a screen or wall. Measure the distance from directly below the front axle to the base of the screen/wall.

4. Draw a horizontal line 35 in. (0.9 m) above ﬂoor on screen/wall.

5. Load vehicle with rider, passenger (if normally present) and any cargo. Weight will compress vehicle suspension slightly.

6. Stand motorcycle upright with both tires resting on ﬂoor and with front wheel held in straight alignment (directly forward).

7. See Figure 1-46. Tu rn ignition switch ON. Set handlebar headlamp switch to HIGH beam position.

8. Check light beam for alignment. a. The main beam, which is a broad, ﬂat pattern of

light, should be centered equally above and below the horizontal line.

b. The main beam of light should also be directed

straight ahead. Properly adjusted headlamps project an equal area of light to right and left of center.

c. Adjust headlamp alignment if necessary.

Figure 1-45. Checking Headlamp Alignment

Figure 1-46. Headlamp Switch High Beam Setting

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ADJUSTMENT

All Models

1. See Figure 1-47. Loosen horizontal adjusting bolt (2) to adjust headlamp beam side to side. Tighten bolt to 25-30 ft-lbs (33.9-40.7 Nm).

2. Loosen nut on vertical adjusting bolt (1) to adjust headlamp beam up or down. Tighten nut to 25-30 ft-lbs (33.9-

40.7 Nm).

11327

1. Vertical adjusting bolt

2. Horizontal adjusting bolt

Figure 1-47. Headlamp Adjustments

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CRITICAL FASTENERS 1.25

INSPECTION

Refer to Ta ble 1-7. Tighten all critical fasteners, except head bolts, to service manual speciﬁcations. Replace any damaged or missing hardware.

Table 1-7. Critical Fasteners

SYSTEM FASTENER TORQUE

Upper and lower switch housings 35-45 in-lbs 4.0-5.1 Nm

Hand controls

Brakes

Axle nuts

Front fork/handlebars

Clutch lever handlebar clamp 60-80 in-lbs 6.8-9.0 Nm Master cylinder handlebar clamp 60-80 in-lbs 6.8-9.0 Nm

Banjo bolts 17-22 ft-lbs 23.0-29.8 Nm

Lower brake caliper mounting pin 28-38 ft-lbs 38.0-51.5 Nm

Brake disc screws, front 16-24 ft-lbs 21.7-32.5 Nm

Brake disc screws, rear 30-35 ft-lbs 40.7-47.5 Nm

Brake disc screws, rear (allen) 23-27 ft-lbs 31.2-36.6 Nm Reservoir screws 6-8 in-lbs 0.7-0.9 Nm

Rear master cylinder mounting nut 40-50 ft-lbs 54.2-67.8 Nm

Front axle 50-55 ft-lbs 67.8-74.6 Nm

Rear axle 60-65 ft-lbs 81.3-88.1 Nm

Lower fork pinch bolts 30-35 ft-lbs 40.7-47.5 Nm Slider bolts 108-156 in-lbs 12.2-17.6 Nm

Upper bracket pinch bolts 21-27 ft-lbs 28.5-36.6 Nm Handlebar clamp mounting screw 70-80 in-lbs 7.9-9.0 Nm Riser clamp screws 144-180 in-lbs 16.3-20.3 Nm

Riser lock nuts 30-40 ft-lbs 40.7-54.2 Nm

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STORAGE 1.26

GENERAL

11WARNING1WARNING

Do not store motorcycle with gasoline in tank within the home or garage where open ﬂames, pilot lights, sparks or electric motors are present. Gasoline is extremely ﬂammable and highly explosive, which could result in death or serious injury. (00003a)

If the motorcycle will not be operated for several months, such as during the winter season, there are several things which should be done to protect parts against corrosion, to preserve the battery, and to prevent the buildup of gum and varnish in the fuel system.

This work should be performed by a local Harley-Davidson dealer or other qualiﬁed technician following the procedures in this service manual.

1. Run motorcycle until engine is at normal operating temperature. Stop the engine then drain the oil pan, install a new oil ﬁlter, and ﬁll oil pan with the proper grade oil. Check the transmission lubricant level.

3. Remove the spark plugs, inject a few squirts of engine oil into each cylinder and crank the engine 5-6 revolutions. Reinstall spark plugs.

4. Inspect rear belt deﬂection. See 1.14 REAR BELT

DEFLECTION.

5. Inspect rear belt and sprockets. See 1.15 REAR BELT

AND SPROCKETS.

6. Inspect air cleaner ﬁlter. See 1.20 AIR CLEANER FIL-

TER.

7. Lubricate controls. See 1.21 CABLE AND CHASSIS

LUBRICATION.

8. Inspect operation of all electrical equipment and switches.

9. Check tire inﬂation and inspect tires for wear and/or damage. See 1.9 TIRES AND WHEELS. If the motorcycle will be stored for an extended period of time, securely support the motorcycle under the frame so that all weight is off the tires.

11WARNING1WARNING

Be sure that brake ﬂuid or other lubricants do not contact brake pads or discs. Such contact can adversely affect braking ability, which could cause loss of control, resulting in death or serious injury. (00290a)

10. Wash painted and chrome-plated surfaces. Apply a light ﬁlm of oil to exposed unpainted surfaces.

11WARNING1WARNING

2. Prepare your fuel system by ﬁlling fuel tank and adding a gasoline stabilizer. Use one of the commercially available gasoline stabilizers following the manufacturer’s instructions.

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11WARNING1WARNING

● Unplug or turn OFF battery charger before connect-

ing charger cables to battery. Connecting cables with charger ON can cause a spark and battery explosion, which could result in death or serious injury. (00066a).

● Explosive hydrogen gas, which escapes during

charging, could cause death or serious injury. Charge battery in a well-ventilated area. Keep open ﬂames, electrical sparks and smoking materials away from battery at all times. KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

11. Remove battery from vehicle. Charge battery until the correct voltage is obtained. Charge the battery every other month if it is stored at temperatures below 60˚ F (16˚ C). Charge battery once a month if it is stored at temperatures above 60˚ F (16˚ C). See 1.5 BATTERY

MAINTENANCE.

1CAUTION

Unplug or turn OFF battery charger before disconnecting charger cables from battery. Disconnecting clamps with charger ON can cause a spark and battery explosion, which could result in death or serious injury. (00067a)

12. If the motorcycle is to be covered, use a material that will breathe, such as light canvas or Part No. 98716-87A. Plastic materials that do not breathe promote the formation of condensation, which leads to corrosion.

REMOVAL FROM STORAGE

The clutch failing to disengage can cause loss of control, which could result in death or serious injury. Prior to starting after extended periods of storage, place transmission in gear and push vehicle back and forth several times to assure proper clutch disengagement. (00075a)

1. Charge and install the battery.

2. Remove and inspect the spark plugs. Replace if necessary.

3. Clean the air cleaner element.

4. If fuel tank was drained, ﬁll fuel tank with fresh gasoline.

5. Start the engine and run until it reaches normal operating temperature.

6. Check engine oil level. Check the transmission lubricant level. Fill to proper levels with correct ﬂuids, if required.

7. Perform all of the checks in the PRE-RIDING CHECKLIST in the Owner’s Manual.

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TROUBLESHOOTING 1.27

GENERAL

11WARNING1WARNING

The troubleshooting section of this manual is a guide to diagnose problems. Read the appropriate sections of this manual before performing any work. Improper repair and/or maintenance could result in death or serious injury.

The following check list of possible operating troubles and their probable causes will be helpful in keeping a motorcycle in good operating condition. More than one of these conditions may be causing the trouble and all should be carefully checked.

ENGINE

Starter Motor Does Not Operate or Does Not Turn Engine Over

1. Ignition switch not in ON position.

2. Engine run switch in OFF position.

3. Discharged battery, loose or corroded connections (solenoid chatters).

4. Starter control circuit, relay, or solenoid faulty.

5. Electric starter shaft pinion gear not engaging or overrunning clutch slipping.

6. TSM/TSSM Bank Angle Sensor tripped and ignition switch not cycled OFF then ON.

Engine Turns Over But Does Not Start

1. Fuel tank empty.

2. Fouled spark plugs.

3. Discharged battery, loose or broken battery terminal connections.

4. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

5. Spark plug cables in bad condition and shorting, cable connections loose or cables connected to incorrect cylinders.

6. Loose wire connection at coil, battery or ECM connector.

7. Ignition timing incorrect due to faulty coil, ECM or sensors (MAP, CKP and/or TSM/TSSM).

Starts Hard

1. Spark plugs in bad condition or have improper gap or are partially fouled.

2. Spark plug cables in bad condition.

3. Battery nearly discharged.

4. Loose wire connection at one of the battery terminals, coil or ECM connector.

5. Water or dirt in fuel system.

6. Intake air leak.

7. Fuel tank vent hose and vapor valve plugged.

8. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

9. Ignition not functioning properly (possible sensor failure).

10. Faulty ignition coil.

11. Valves sticking.

Starts But Runs Irregularly or Misses

1. Spark plugs in bad condition or partially fouled.

2. Spark plug cables in bad condition and leaking.

3. Spark plug gap too close or too wide.

4. Faulty ignition coil, ECM, or sensor.

5. Battery nearly discharged.

6. Damaged wire or loose connection at battery terminals, coil or ECM connector.

7. Intermittent short circuit due to damaged wire insulation.

8. Water or dirt in fuel system.

9. Fuel tank vent system plugged.

10. Air leak at intake manifold or air cleaner.

11. Loose or dirty ECM connector.

12. Faulty Sensor(s): Manifold Absolute Pressure (MAP), Crank Position (CKP) or Oxygen (O2).

13. Incorrect valve timing.

14. Weak or broken valve springs.

15. Damaged intake or exhaust valve.

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A Spark Plug Fouls Repeatedly

1. Fuel mixture too rich.

2. Incorrect spark plug for the kind of service.

3. Piston rings badly worn or broken.

4. Valve guides or seals badly worn.

Pre-Ignition or Detonation (Knocks or Pings)

1. Fuel octane rating too low.

2. Faulty spark plugs.

3. Incorrect spark plug for the kind of service.

4. Excessive carbon deposit on piston head or in combustion chamber.

5. Ignition timing advanced due to faulty sensor inputs (MAP and/or CKP).

Overheating

1. Insufﬁcient oil supply or oil not circulating.

2. Insufﬁcient air ﬂow over engine.

3. Heavy carbon deposit.

4. Ignition timing retarded due to faulty sensor(s): Manifold Absolute Pressure (MAP) and/or Crank Position (CKP).

5. Leaking valve.

Valve Train Noise

1. Low oil pressure caused by oil feed pump not functioning properly or oil passages obstructed.

2. Faulty hydraulic lifters.

3. Bent push rod.

4. Incorrect push rod length.

5. Rocker arm binding on shaft.

6. Valve sticking in guide.

7. Chain tensioner or shoe worn.

Excessive Vibration

1. Wheels and/or tires worn or damaged.

2. Engine/transmission/rear wheel not aligned properly.

3. Primary chain badly worn or links tight as a result of insufﬁcient lubrication or misalignment.

4. Engine to transmission mounting bolts loose.

5. Upper engine mounting bracket loose.

6. Ignition timing advanced due to faulty sensor inputs (MAP and/or CKP)/poorly tuned engine.

7. Internal engine problem.

8. Broken frame.

Check Engine Light Illuminates During Operation

1. Fault detected. See CHECKING FOR TROUBLE CODES in DYNA MODELS ELECTRICAL DIAGNOSTIC MANUAL for more information.

LUBRICATION SYSTEM

Oil Does Not Return To Oil Pan

1. Oil pan empty.

2. Oil pump not functioning.

3. Restricted oil lines or ﬁttings.

4. Restricted oil ﬁlter.

5. Oil pump misaligned or in poor condition.

6. O-ring damaged or missing from oil pump/crankcase junction (also results in poor engine performance).

Engine Uses Too Much Oil Or Smokes Excessively

1. Oil pan overﬁlled.

2. Restricted oil return line to pan.

3. Restricted breather operation.

4. Restricted oil ﬁlter.

5. Oil pump misaligned or in poor condition.

6. Piston rings badly worn or broken.

7. Valve guides or seals worn.

8. O-ring damaged or missing from oil pump/crankcase junction (also results in poor engine performance).

9. Plugged crankcase scavenge port.

Engine Leaks Oil From Cases, Push Rods, Hoses, Etc.

1. Loose parts.

2. Imperfect seal at gaskets, push rod cover, washers, etc.

3. Restricted breather hose to air cleaner.

4. Restricted oil ﬁlter.

5. Oil pan overﬁlled.

6. Lower rocker housing gasket installed incorrectly (upside down).

7. Restricted oil return line to tank.

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1. Oil pan underﬁlled.

2. Faulty low oil pressure switch.

3. Oil pump O-ring damaged or missing.

4. Bypass valve stuck in open position.

5. Ball missing or leaking in cam support plate.

1. Oil pan overﬁlled.

2. Bypass valve stuck in closed position.

1. Voltage regulator/rectiﬁer module not grounded.

2. Engine ground wire loose or broken.

3. Faulty regulator-rectiﬁer module.

4. Loose or broken wires in charging circuit.

5. Faulty stator and/or rotor.

1. Primary chaincase overﬁlled with lubricant.

2. Clutch dragging slightly.

3. Transmission lubrication too heavy (winter operation).

4. Shifter return spring (inside transmission) bent or broken.

5. Bent shifter rod.

6. Shifter forks (inside transmission) sprung.

7. Corners worn off shifter dog rings (inside transmission).

1. Shifter rod improperly adjusted.

2. Shifter drum (inside transmission) damaged.

3. Shifter engaging parts (inside transmission) badly worn and rounded.

4. Shifter forks bent.

5. Damaged gears.

1. Weak or damaged battery.

2. Loose connections.

3. Faulty regulator-rectiﬁer module.

4. Faulty stator and/or rotor.

1. Contaminated vehicle speed sensor (remove sensor and clean off metal particles).

2. Loose connections.

1. Clutch controls improperly adjusted.

2. Insufﬁcient clutch spring tension.

3. Worn friction discs.

1. Lubricant level too high in primary chaincase.

2. Clutch controls improperly adjusted.

3. Primary chain badly misaligned.

4. Clutch spring tension.

5. Clutch discs warped.

1. Friction discs or steel discs worn or warped.

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HANDLING

Irregularities

1. Improperly loaded motorcycle. Non-standard equipment on the front end such as heavy radio receivers, extra lighting equipment or luggage tends to cause unstable handling.

2. Damaged tire(s) or improper front-rear tire combination.

3. Irregular or peaked front tire tread wear.

4. Incorrect tire pressure. See 1.9 TIRES AND WHEELS.

5. Shock absorber not functioning normally.

6. Loose wheel axle nuts. Tighten to recommended torque speciﬁcation.

7. Excessive wheel hub bearing play.

8. Rear wheel out of alignment with frame and front wheel.

9. Steering head bearings improperly adjusted. Correct adjustment and replace pitted or worn bearings and races. See 1.17 STEERING HEAD BEARINGS.

10. Loose spokes (laced wheel vehicles only).

11. Tire and wheel unbalanced.

12. Rims and tires out-of-round or eccentric with hub.

13. Rims and tires out-of-true sideways.

14. Rear fork pivot.

BRAKES

Brake Does Not Hold Normally

1. Master cylinder reservoir low on ﬂuid.

2. Brake system contains air bubbles.

3. Master cylinder or caliper piston seals worn or parts damaged.

4. Brake pads contaminated with grease or oil.

5. Brake pads badly worn.

6. Brake disc badly worn or warped.

7. Brake drags – insufﬁcient brake pedal freeplay.

8. Brake fades due to heat build up – brake pads dragging or excessive braking.

9. Brake ﬂuid leak when under pressure.

2006 Dyna: Maintenance 1-53

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NOTES

1-54 2006 Dyna: Maintenance

Page 57

CHASSIS 2

able Of Contents

SUBJECT PAGE NO.

2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Vehicle Identification Number (V.I.N.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.4 Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.5 Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.6 Sealed Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.7 Wheel Lacing: 17 In. Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.8 Wheel Lacing: 19 In. Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.9 Wheel Lacing: 21 In. Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2.10 Truing Laced Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2.11 Cast Wheel Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

2.12 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

2.13 Vehicle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2.14 Front Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

2.15 Rear Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

2.16 Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

2.17 Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

2.18 Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

2.19 Steering Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

2.20 Rear Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

2.21 Rear Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

2.22 Belt Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

2.23 Debris Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

2.24 Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

2.25 Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

2.26 Front Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

2.27 Rear Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

2.28 Jiffy Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

2.29 Fork Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

2.30 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

2.31 Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

Page 58

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SPECIFICATIONS 2.1

ITEM

Wheel base 64.2 1630 64.2 1630 64.6 1640 68.3 1735 64.2 1630 64.2 1630 Overall length 92.8 2357 92.6 2353 93.1 2364 97.5 2477 92.9 2360 92.8 2358 Overall width 36.7 931 34.9 886 36.3 921 36 915 38.9 989 37.5 953 Road clearance 6.0 153 6.0 153 5.6 142 6.2 158 6.0 153 5.6 142 Overall height 46.8 1189 47.6 1210 47.0 1194 49.3 1251 47.7 1212 50.4 1279 Saddle height 27.6 700 27.8 705 26.8 680 28.5 723 27.8 705 26.8 680

MODEL

FXDWG/FXD35 29.6** 0.875** 5.1 19.3 1.2 4.5 FXDL/FXDB/

FXD35 FXD/C 4.8 18.2 0.8-1.2 3.0-4.5 * Reserve when low fuel light illuminates.

**FXD35 fork ﬂuid capacity is same as FXD

FXD FXDC FXDL FXDWG FXD35 FXDB

in. mm in. mm in. mm in. mm in. mm in. mm

FRONT FORK

oz. liter gal. liter gal. liter qt. liter oz. liter oz. liter

26.6 0.787

FUEL TANK

TOTAL

4.7 17.8 0.8-1.2 3.0-4.5

FUEL TANK

RESERVE *

OIL TANK

W/FILTER

3.0 2.8 32.0 0.95 32.0 0.95

TRANSMISSION

(APPROX.)

PRIMARY

CHAINCASE

ITEM

Weight (as shipped from factory)

GVWR 1085 493 1085 493 1085 493 1085 493 1085 493 1085 493 GAWR front 390 177 390 177 390 177 390 177 390 177 390 177 GAWR rear 695 316 695 316 695 316 695 316 695 316 695 316

Gross vehicle weight rating (GVWR) (maximum allowable loaded vehicle weight) and corresponding gross axle weight rating (GAWR) are given on a label located on the frame steering head.

FXD FXDC FXDL FXDWG FXD35 FXDB

lb. kg lb. kg lb. kg lb. kg lb. kg lb. kg

632 287 641 291 641 291 650 295 645 293 634 285

NOTE

See 1.9 TIRES AND WHEELS for important information regarding tire data and tire inﬂation.

NOTE

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TORQUE VALUES 2.2

ITEM TORQUE NOTES

Axle cap fastener 12 ft-lbs 16.3 Nm page 2-10

Belt guard fasteners 10-15 ft-lbs 13.6-20.3 Nm page 2-70

Belt sprocket screws 55-60 ft-lbs 74.6-81.3 Nm

Brake disc screws, front 16-24 ft-lbs 21.7-32.5 Nm page 2-8

Brake disc screws, rear 30-45 ft-lbs 40.7-61.0 Nm

Debris deﬂector screws 40-60

Fork stem nut 35-40 ft-lbs 47.5-54.2 Nm page 2-65

Fork tube caps 16-43 ft-lbs 22-58 Nm page 2-62

Front axle nut 50-55 ft-lbs 67.8-74.6 Nm page 2-9

Front brake caliper bleeder valve

Front brake caliper bridge bolts 28-38 ft-lbs 38.0-51.5 Nm page 2-50

Front brake caliper lower mounting bolt

Front brake caliper top mounting bolt

Front brake reservoir cover screws

Front fender nuts 15-21 ft-lbs 20.3-28.5 Nm page 2-75

in-lbs

80-100

in-lbs

28-38 ft-lbs 38.0-51.5 Nm Short bolt, 12 pt/10 mm, page 2-11, page 2-51

28-38 ft-lbs 38.0-51.5 Nm Long bolt, 12 pt/10 mm, page 2-11, page 2-51

6-8

in-lbs

4.5-6.8 Nm page 2-14, page 2-71

9.0-11.3 Nm page 2-50

0.7-0.9 Nm page 2-52

Apply several drops of LOCTITE® thread locker 262 (red) to last few threads. page 2-12

Apply several drops of LOCTITE® thread locker 243 (blue) to last few threads. page 2-12

Front master cylinder banjo bolt

Isolator mounting bolts 25 ft-lbs 33.9 Nm page 2-38

Jiffy stand bolt 19 ft-lbs 25.8 Nm page 2-79

Lower shock mounting fasteners

Master cylinder clamp screw 70-80

Pivot shaft nut 71-75 ft-lbs 96.3-101.7 Nm page 2-69

Rear axle nut 60-65 ft-lbs 81.3-88.1 Nm page 2-14

Rear brake caliper bleeder valve

Rear brake caliper bridge bolts 28-38 ft-lbs 38.0-51.5 Nm page 2-56

Rear brake pad pins 15-16 ft-lbs 20.3-22.6 Nm 12 pt/0.25 in., page 2-51, page 2-57

Rear brake reservoir cover screws

Rear master cylinder banjo bolt

Rear master cylinder mounting nut

17-22 ft-lbs 23.0-29.8 Nm page 2-43

30-40 ft-lbs 40.7-54.2 Nm page 2-14, page 2-67

in-lbs

80-100

in-lbs

6-8

in-lbs

17-22 ft-lbs 23.0-29.8 Nm page 2-47

40-50 ft-lbs 54.2-67.8 Nm page 2-47

7.9-9.0 Nm T27 TORX, page 2-43

9.0-11.3 Nm page 2-56

0.7-0.9 Nm page 2-47

2-2 2006 Dyna: Chassis

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ITEM TORQUE NOTES

Seat pipe screw 106-159

Seat strap nut 60-90

Spoke nipples 55-65

Throttle housing screws 35-45

Upper shock mounting fasteners

Valve stem nut 12-15

Wheel spoke nipples 55-65

75-85 ft-lbs 101.7-115.2 Nm page 2-14

75-85 ft-lbs 101.7-115.2 Nm page 2-67

in-lbs

12-18 Nm page 2-62

6.78-10.17 Nm page 2-81

6.2-7.3 Nm page 2-20, page 2-25, page 2-28

4.0-5.1 Nm page 2-72

1.4-1.7 Nm page 2-34

6.2-7.3 Nm page 2-31

2006 Dyna: Chassis 2-3

Page 62

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VEHICLE IDENTIFICATION NUMBER (V.I.N.) 2.3

GENERAL

See Figure 2-1. The full 17 digit serial, or Vehicle Identiﬁca- tion Number (V.I.N.) is stamped on the right side of the steering head and on a label located on the right side down tube.

An abbreviated V.I.N. is stamped on the left side crankcase at the base between the cylinders.

Sample V.I.N. as it appears on the steering head -

1HD1GP1116K110000

Sample abbreviated V.I.N. as it appears on the left crankcase

GP16110000

NOTE

Always give the full 17 digit Vehicle Identiﬁcation Number when ordering parts or making any inquiry about your motorcycle.

12209

1. Stamping

2. Label

Figure 2-1. V.I.N. Location

1HD1GP 1 1 8 6 K 300000

Figure 2-2. Dyna Vehicle Identiﬁcation Number (typical

Table 2-1. 2006 Dyna Model

V.I.N. Codes

CODE MODEL NAME

GM FXD

GN FXDL

GP FXDWG

GV FXDC

GW FXD35

GX FXDB

2-4 2006 Dyna: Chassis

Page 63

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Table 2-2. Harley-Davidson 2006 Dyna Model V.I.N. Description

ITEM DESCRIPTION POSSIBLE VALUES

1 Market destination 1=Originally manufactured for sale within

States 5=Originally manufactured for sale outside States

2 Manufacturer and make HD=Harley-Davidson

3 Motorcycle type 1=Heavyweight motorcycle 901 cc and larger

4 Model see model V.I.N. table

5 Engine type 1=Twin Cam 88, 1450cc air-cooled, fuel injected

6 Introduction date 1=Regular

2=Mid-year 3=California/regular 4=Cosmetic changes and/or special introductory date 5=California/cosmetic changes and/or special introductory date 6=California/mid-year

7 VIN check digit Can be 0-9 or X

8 Model year 6=2006

9 Plant of manufacture K=Kansas City, MO., U.S.A.

10 Sequential number (last 6 digits) varies

the United

of the United

2006 Dyna: Chassis 2-5

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FRONT WHEEL 2.4

REMOVAL

1. Block motorcycle underneath frame so front wheel is raised off the ground.

2. Inspect wheel bearing end play and service bearings if necessary. See 2.6 SEALED WHEEL BEARINGS.

3. See Figure 2-3. Remove brake caliper. Support caliper using a rubber bungee cord.

CAUTION

Be careful not to scratch the fender paint.

NOTE

Do not operate front brake lever with the front wheel removed or the caliper piston may be forced out of piston bore. Reseating the piston requires disassembly of the caliper.

4. Remove axle nut, lockwasher and washer (3).

5. See Figure 2-4. Loosen the slider cap screws (2) and pull the axle (1) free.

12206

1. Axle

2. Slider cap screws and washers (metric)

Figure 2-4. Front Wheel Mounting (Right Side)

6. Remove wheel from forks.

11329

1. Long mounting bolt (12 pt/10 mm)

2. Short mounting bolt (12 pt/10 mm)

3. Axle nut, lockwasher and washer

Figure 2-3. Caliper Mounting Bolts (Left Side)

2-6 2006 Dyna: Chassis

Page 65

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1. Axle

2. Right bearing spacer

3. Screw (5)

4. Washer (5)

5. Bearing (2)

6. Sleeve

7. Cast wheel

8. Brake disc

9. Left bearing spacer

10. Washer

11. Lockwasher

12. Axle nut

1. Axle

2. Right bearing spacer

3. Screw (5)

4. Screw (5)

5. Bearing (2)

6. Sleeve

7. Wheel hub

8. Brake disc

9. Left bearing spacer

10. Washer

11. Lockwasher

12. Axle nut

13. Valve stem nut

14. Valve cap

15. Spoke & nipple kit

16. Balance weight

17. Rim

18. Laced wheel assembly

19. Hubcap (not on FXDWG & FXD)

Figure 2-5. Cast Front Wheel

d0451a2x

Figure 2-6. Laced Front Wheel

d0593a2x

2006 Dyna: Chassis 2-7

Page 66

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DISASSEMBLY

NOTE

See 2.12 TIRES to service tire or valve stem assembly.

Cast Wheel

1. See Figure 2-5. Remove spacers (2, 9) from left and right sides.

2. If necessary, remove brake disc (8). On left side of wheel, remove ﬁve screws (3) and washers (4) to detach brake disc (8).

3. Label all components so they may be installed in their original locations.

Laced Wheel

1. See Figure 2-6. Remove spacers (2, 9) from left and right sides.

2. If necessary, remove brake disc(s) (8). On left side of wheel, remove ﬁve screws (3) to detach brake disc (8).

3. Label all components so they may be installed in their original locations.

CLEANING AND INSPECTION

1. Inspect all parts for damage or excessive wear.

11WARNING1WARNING

Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a)

2. Inspect brake rotor and pads. See 1.8 BRAKE PADS

AND DISCS.

ASSEMBLY

Cast Wheel

11WARNING1WARNING

1. See Figure 2-5. If necessary, install brake disc (8). Verify that brake disc is clean.

2. On left side of wheel, install ﬁve washers (4) to attach brake disc (8). Tighten fasteners to 16-24 ft-lbs (21.7-32.5 Nm).

3. Install spacers (2, 9) with largest chamfered end facing away from wheel.

4. Verify that wheel and tire are true. See 2.11 CAST

WHEEL RUNOUT.

new

screws (3) and

Laced Wheel

1. If hub and rim were disassembled, see, 2.8 WHEEL

LACING: 19 IN. RIM, or 2.9 WHEEL LACING: 21 IN. RIM.

11WARNING1WARNING

1. See Figure 2-5. If necessary, install brake disc (8). Verify that brake disc is clean.

2. On left side of wheel, install ﬁve washers (4) to attach brake disc (8). Tighten fasteners to 16-24 ft-lbs (21.7-32.5 Nm).

3. Install spacers (2, 9) with largest chamfered end facing away from wheel.

4. Verify that wheel and tire are true. See 2.10 TRUING

LACED WHEEL

new

screws (3) and

2-8 2006 Dyna: Chassis

Page 67

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1. Spacer (2)

2. Axle nut, lockwasher and washer

3. Slider cap screws

11330

12208

1. Fork slider

2. Axle

3. 7/16 in. Drill bit

4. Rear axle cap fastener

5. Axle cap

6. Front axle cap fastener

INSTALLATION

1. Apply a light coat of LOCTITE ANTI-SEIZE LUBRICANT to the axle.

2. See Figure 2-7. Place wheel into front fork and install axle. Verify that axle spacers (1) on right and left side are properly installed.

3. Install the washer, lockwasher, and slider cap screws. Tighten axle nut to 50-55 ft-lbs (67.8-74.6 Nm). Hold axle stationary with a steel rod or screwdriver inserted through hole on right end of axle while tightening.

4. See Figure 2-8. a. Loosen axle cap fasteners. b. Insert 7/16 in. drill bit (2) as far as it will go into hole

in axle (1).

c. Position fork leg against edge of drill bit. Contact

point must the have edge of drill bit touching the edge of fork leg.

Figure 2-7. Front Axle Assembly

Figure 2-8. Fork Alignment

2006 Dyna: Chassis 2-9

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d. See Figure 2-9. With cast in spacer (1) of axle cap

facing rear of vehicle, tighten rear axle cap fastener (2) to 12 ft-lbs (16.3 Nm) while holding slider against 7/16 drill bit if necessary.

e. While holding slider against 7/16 drill bit if neces-

sary, tighten front axle cap fastener to 12 ft-lbs (16.3 Nm). Remove drill bit.

5. See Figure 2-3. Install the brake caliper to the fork legs. a. Loosely install long mounting bolt (1) (12 pt/10 mm)

into top hole on fork leg.

b. Install short mounting bolt (2) (12 pt/10 mm) into

bottom hole on fork leg. Tighten bottom mounting bolt to 28-38 ft-lbs (38.0-51.5 Nm).

c. Final tighten the top mounting bolt to 28-38 ft-lbs

(38.0-51.5 Nm).

11WARNING1WARNING

Whenever a wheel is installed and before moving the motorcycle, pump brakes to build brake system pressure. Insufﬁcient pressure can adversely affect brake performance, which could result in death or serious injury. (00284a)

6. Pump brake hand lever to move pistons out until they contact both brake pads. Verify piston location against pads.

12206

1. Cast in spacer

2. Rear axle cap fastener

3. Front axle cap fastener

4. gap

Figure 2-9. Axle cap

2-10 2006 Dyna: Chassis

Page 69

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1. Retaining ring

2. Axle nut

3. Washer

11324

REAR WHEEL 2.5

REMOVAL

1. Block motorcycle underneath frame so rear wheel is raised off the ground.

2. Remove three screws to detach the debris deﬂector from rear fork. See 2.23 DEBRIS DEFLECTOR.

3. Inspect wheel bearing end play and service bearings if necessary. See 2.6 SEALED WHEEL BEARINGS.

4. See Figure 2-10. Remove retaining ring (1), axle nut (2), and washer (3) from left side of axle.

5. See Figure 2-11. Loosen, but do not remove, left and right

upper

mounting screws (1).

6. Remove left and right

7. Allow rear fork and wheel to lower.

8. Remove belt guard. See 2.22 BELT GUARD.

9. Pry brake pads away from rotor.

10. Remove retaining pins and brake pads. See 1.8 BRAKE

PADS AND DISCS.

Caliper to rear wheel clearance is minimal. To prevent damage to surfaces, be careful when removing caliper from rear fork.

11. Remove caliper assembly from rear fork. See 2.17 REAR

BRAKE CALIPER in this section.

12. Remove axle from wheel.

13. Move wheel forward and slip belt off sprocket.

Tension may have to be relieved before belt will slip off. Spacer may fall out when tension is relieved.

14. Pull wheel and belt sprocket from rear fork.

Do not operate rear brake pedal with the rear wheel removed or the caliper piston may be forced out of piston bores. Reseating the piston requires disassembly of the caliper.

lower

shock mounting screws (2).

NOTE

Figure 2-10. Rear Axle

2006 Dyna: Chassis 2-11

Page 70

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DISASSEMBLY

NOTE With the exception of the sprocket cover (13), component parts for cast and laced rear wheels are identical.

1. See Figure 2-12. Remove spacers (2, 11) from left and

right sides.

2. If necessary, remove brake disc and/or rear sprocket.

Label components so they may be installed in their original locations.

a. On left side of wheel, remove ﬁve screws (15) and

washers (16) to detach rear sprocket (9).

b. On right side of wheel, remove ﬁve screws (3) to

remove rear brake disc (4).

ASSEMBLY

1. If hub and rim were disassembled, see 2.7 WHEEL LAC-

ING: 17 IN. RIM, 2.8 WHEEL LACING: 19 IN. RIM, or 2.9 WHEEL LACING: 21 IN. RIM.

2. See Figure 2-12. Install brake disc (4) on valve stem side

of wheel if removed. a. Apply a drop of LOCTITE THREADLOCKER 243

(blue) to the ﬁve screws (3).

b. Tighten to 30-45 ft-lbs (40.7-61.0 Nm).

d0797x2x

1. Upper mounting screws (2)

2. Lower mounting screws (2)

Figure 2-11. Rear Shock Mount

CLEANING AND INSPECTION

1. Inspect all parts for damage or excessive wear.

11WARNING1WARNING

Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a)

2. Inspect brake rotor and pads. See 1.8 BRAKE PADS

AND DISCS.

3. Inspect rear belt and sprocket. 1.15 REAR BELT AND

SPROCKETS.

4. Install belt sprocket (9) if removed.

a. Apply two drops of LOCTITE THREADLOCKER 262

(red) to the ﬁve screws (15). Install sprocket using screws (15) and washers (16).

b. Tighten screws to 55-60 ft-lbs (74.6-81.3 Nm).

5. Install spacers (2, 10) into hub with largest chamfered

end facing away from wheel.

6. Verify that wheel and tire are true.

a. For laced wheels, see 2.10 TRUING LACED

WHEEL.

b. For cast wheels, see 2.11 CAST WHEEL RUNOUT.

2-12 2006 Dyna: Chassis

Page 71

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1. Axle

2. Right bearing spacer

3. Screw (5)

4. Rear brake disc

5. Bearing (2)

6. Sleeve

7. Cast wheel

8. Laced wheel hub and rim

9. Rear sprocket

10. Left bearing spacer

11. Washer

12. Axle nut

13. Sprocket cover (FXD35 only)

14. Retaining

15. Screw (5)

16. Washer (5)

d0452a2x

Figure 2-12. Rear Wheel/Hub

2006 Dyna: Chassis 2-13

Page 72

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INSTALLATION

1. Roll wheel into rear fork and position brake disc side

spacer between wheel and fork.

2. Slide drive belt over drive sprocket. Make sure brake disc

is centered between brake pads.

3. Coat axle with LOCTITE ANTI-SEIZE LUBRICANT and

install. a. From right side, carefully insert axle through right

rear fork, rear caliper bracket, right side spacer and brake disc.

b. Continue sliding axle through wheel hub sleeve,

sprocket, left side spacer and left rear fork.

NOTE Caliper to rear wheel clearance is minimal. To prevent damage to surfaces, be careful when removing caliper from rear fork.

4. Install caliper assembly to rear fork. See 2.17 REAR

BRAKE CALIPER in this section.

5. Install brake pads and retaining pins. See 1.8 BRAKE

PADS AND DISCS.

6. See Figure 2-11. Attach rear shocks.

a. Apply two or three drops of LOCTITE THREAD-

LOCKER 243 (blue) to threads of lower shock mounting screws (2).

b. Lift rear fork and install both shock absorbers with

lower shock mounting screws (2)

c. Tighten upper shock fasteners to 75-85 ft-lbs (101.7-

115.2 Nm).

d. Tighten lower shock fasteners to 30-40 ft-lbs (40.7-

54.2 Nm).

11WARNING1WARNING

7. See Figure 2-10. Install washer (3) and axle nut (2) on left side of axle.

a. Tighten axle nut to 60-65 ft-lbs (81.3-88.1 Nm). b. Install retaining ring (1).

8. Install debris deﬂector using three screws. Tighten to 4060

in-lbs

(4.5-6.8 Nm). See 2.23 DEBRIS DEFLECTOR.

9. Install belt guard. See 2.22 BELT GUARD.

11WARNING1WARNING

10. Pump brake pedal to move pistons out until they contact both brake pads. Verify piston location against pads.

11. Verify correct axle alignment (2.13 VEHICLE ALIGN-

MENT) and then check belt deﬂection (1.14 REAR BELT DEFLECTION).

2-14 2006 Dyna: Chassis

Page 73

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d0606x2x

1. Forcing screw

2. Nut

3. Washer

4. Nice bearing

5. Bridge

6. Collet with ball bearing inside

d0559x2x

SEALED WHEEL BEARINGS 2.6

INSPECTION

1. Block motorcycle underneath frame so wheel is raised off the ground.

2. See Figure 2-13. Mount a magnetic base dial indicator to the brake disc with the dial’s contact point on the end of the axle.

3. Turn the wheel through several rotations, then move the wheel side to side to check for end play.

a. If the end play is less than the service wear limit of

0.002 in. (0.051 mm), bearing passes inspection.

b. If end play exceeds service wear limit or feels rough,

remove wheel and replace both wheel bearings.

REMOVAL

PART NO.

HD-44060 Wheel bearing installer/remover

1. Remove wheel from motorcycle. See 2.4 FRONT

WHEEL or 2.5 REAR WHEEL as appropriate. If present,

remove hub plate from wheel on opposite side of front brake disc.

2. See Figure 2-14. Obtain WHEEL BEARING INSTALLER/ REMOVER (Part No. HD-44060) and assemble.

a. Sparingly apply graphite lubricant to threads of forc-

ing screw (1) to prolong service life and ensure smooth operation.

b. Install nut (2), washer (3) and Nice bearing (4) on

screw. Insert assembly through hole in bridge (5).

c. Drop ball bearing inside collet (6). Fasten collet and

ball bearing to forcing screw (1).

SPECIALTY TOOL

Figure 2-13. Wheel Bearing Inspection

(Front Wheel Shown)

Figure 2-14. Removal Tool

2006 Dyna: Chassis 2-15

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3. Hold end of forcing screw (1) and turn collet (6) to expand edges of collet.

4. See Figure 2-15. When expanded collet has gripped bearing edges, hold end of forcing screw (1) and turn the nut (2) to remove bearing from wheel.

5. Remove spacer from inside wheel hub.

6. Repeat procedure for opposite side bearing. Discard all bearings upon removal.

INSTALLATION

PART NO.

HD-44060 Wheel bearing installer/remover

Always install ﬁrst bearing on primary brake disc side. If front wheel has two brake discs, install bearing on the left side ﬁrst.

1. Obtain WHEEL BEARING INSTALLER/REMOVER (Part No. HD-44060) and assemble.

a. Sparingly apply graphite lubricant to threads of

threaded rod to prolong service life and ensure smooth operation.

b. See Figure 2-16. Place threaded rod through sup-

port plate. Insert assembly through wheel.

c. See Figure 2-17. Place the

(1) with lettered side facing away from wheel centerline.

d. Install pilot (5), Nice bearing (4), washer (3) and nut

(2) over rod.

2. Hold hex end of threaded rod (1) and turn nut (2) to install bearing (6). Bearing will be fully seated when nut can no longer be turned. Remove tool.

3. Install spacer inside wheel hub.

4. Reverse tool and install opposite side bearing.

SPECIALTY TOOL

NOTE

new

bearing (6) on rod

d0560x2x

1. Forcing screw

2. Nut

Figure 2-15. Remove Bearing

d0561x2x

Figure 2-16. Installation Tool Support Plate

d0562x2x

2-16 2006 Dyna: Chassis

1. Threaded rod

2. Nut

3. Washer

4. Nice bearing

5. Pilot

6. Wheel bearing

Figure 2-17. Installing Bearing

Page 75

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d0563x2x

Parts 1-7 common to removal/installation. Parts 8-9 used for removal only. Parts 10-13 used for installation only.

Figure 2-18. Wheel Bearing Remover/Installer (Part No. HD-44060)

NO. DESCRIPTION PA RT NO.

1Bridge HD-44060-5 2 Steel ball 12547

3Forcing screw HD-44060-4 4 Nut 10210 5Washer 12004 6 Nice bearing RS25100-200 7 Lubricant J-23444A 8 Collet, 3/4 in. (FXDWG only) HD-44060-3

9 Collet, 1.0 in. HD-44060-7 10 Pilot, 1.0 in. HD-44060-8 11 Pilot, 3/4 in. (FXDWG only) HD-44060-6 12 Support plate HD-44060-1 13 Threaded rod 280856

2006 Dyna: Chassis 2-17

Page 76

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WHEEL LACING: 17 IN. RIM 2.7

GENERAL

NOTE If only rim is to be replaced, tape spokes together to hold position on hub and remove spokes from rim. Install taped hub/spoke assembly to new rim and tighten spokes. Then remove tape and true wheels.

11WARNING1WARNING

Avoid using oils that attack or contribute to the deterioration of rubber materials. Use of unsuitable oils may lead to premature tire failure, which could result in death or serious injury.

d0459x2x

PROCEDURE

1. Place the hub on table with brake disc side (narrow ﬂange) up. Insert a spoke in each hole of the as shown below. Angle spokes clockwise.

d0456x2x

Figure 2-20.

2. Center the rim over the hub assembly with the valve stem hole facing upward.

3. Using any rim hole to the left of the valve stem hole on the upper half of the rim centerline.

lower

row spoke, place the ﬁrst spoke into the

Narrow flange

lower

row

Figure 2-19.

d0457x2x

Figure 2-21.

2-18 2006 Dyna: Chassis

Page 77

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d0463x2x

4. Install the rest of lower row spokes in every fourth hole.

d0458x2x

Figure 2-22.

Figure 2-25.

5. Place the ﬁrst

upper

row spoke into the hub as shown below. Angle the spoke counterclockwise crossing four lower row spokes. The spoke must enter the hole to the left of the valve stem hole.

d0461x2x

Figure 2-23.

6. Install the remaining nine upper row spokes into every fourth remaining hole above the rim centerline.

d0462x2x

Figure 2-24.

7. Turn rim over so brake disc side (narrow ﬂange) faces down. Place any

lower

row spoke into hub. Angle spoke

clockwise and place into rim hole angled to accept it.

2006 Dyna: Chassis 2-19

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8. Place the remaining nine lower row spokes, angled clockwise, into hub and rim.

d0464x2x

Figure 2-26.

9. Insert any

upper

row spoke into hub and angle spoke

counterclockwise. Place spoke into appropriate rim hole.

10. Install remaining nine upper row spokes.

d0466x2x

Figure 2-28.

11. Tighten spoke nipples to 55-65

in-lbs

(6.2-7.3 Nm).

12. True wheel. See 2.10 TRUING LACED WHEEL.

d0465x2x

Figure 2-27.

2-20 2006 Dyna: Chassis

Page 79

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d0660x2x

1. Outer spoke (short head)

2. Inner spoke (long head)

d0661x2x

WHEEL LACING: 19 IN. RIM 2.8

PROCEDURE

1. Divide spokes into two groups.

a. Inner spokes have long heads. b. Outer spokes have short heads.

11WARNING1WARNING

Avoid using oils that attack or contribute to the deterioration of rubber materials. Use of unsuitable oils may lead to premature tire failure, which could result in death or serious injury.

2. Lubricate spoke threads and nipple shoulders with tire

mounting lubricant.

3. See Figure 2-29. Place hub on bench with the brake disc

side up. On dual-disc wheel hubs, this is the side with the cast recesses between the brake disc bolt holes. Insert one outer spoke (short head) into any bottom ﬂange hole and swing it clockwise. Insert an inner spoke (long head) in the next hole to the left of the outer spoke. Swing the inner spoke counterclockwise over the outer spoke.

4. Find the hole in the upper ﬂange directly above the two

spokes just inserted. This hole uses a long head inner spoke. Insert inner spoke into the hole on the upper ﬂange that directly bisects the two spokes in the bottom ﬂange. Insert all remaining spokes in upper ﬂange alternating the inner and outer spokes.

5. After one ﬂange side is completed ﬂip wheel hub upside

down and repeat to ﬁnish other ﬂange.

6. See Figure 2-30. With all forty spokes inserted in hub,

group all spokes on top ﬂange into two bundles. Secure each group with throttle grips to keep the spokes together.

Figure 2-29. Lacing 19-in. Wheel Hub

Figure 2-30. Bundling Top Spokes

2006 Dyna: Chassis 2-21

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7. Swing all bottom ﬂange outer spokes (short head) clockwise.

8. Swing the inner spokes (long head) counterclockwise, crossing over the outer spokes (short head).

9. Angle all spokes as far as they will go without overlapping the next LIKE spoke. For instance, swing an inner spoke (long head) counter clockwise across four spokes as far as it will go before crossing another inner spoke (laced in a cross-four pattern).

NOTES

All inside spokes lay over all outside spokes.

●

See Figure 2-31. The valve stem hole is centered of the rim; you do not have to worry about choosing the correct relationship between the rim and the hub.

10. Center the rim over the hub assembly.

NOTE:

It is recommended that you lace the ﬁrst spoke next to the valve stem hole. When lacing your ﬁrst spoke, place spoke nipples through several rim holes to determine the correct lacing direction. Only one spoke will ﬁt into the spoke nipple correctly. When connecting the spoke to the spoke nipple, ﬁnger tighten two to three threads.

11. Straighten any spokes that were accidentally bumped or moved on the bottom ﬂange.

12. Work with the bottom ﬂange of outer spokes (short head) ﬁrst.

13. See Figure 2-32. Using the spoke alignment method discussed previously, Locate a hole pointing downward and outward toward the bottom ﬂange of outer spokes (short head).

a. Verify outer spoke (short head) reaches the spoke

nipple and secure spoke loosely by hand. Skip three rim holes and repeat lacing. Follow pattern to complete bottom ﬂange outer spokes (short head).

b. See Figure 2-33. Once you have completed lacing

the bottom row of outer spokes (short head) double check for three empty holes in between each spoke.

d0662x2x

Figure 2-31. Valve Stem Hole Location

d0663x2x

Figure 2-32. Beginning Spoke: Bottom Flange Outer

d0664x2x

2-22 2006 Dyna: Chassis

Figure 2-33. Completed Spokes: Bottom Flange Outer

Page 81

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14. Work with bottom ﬂange inner spokes (long head) next. Choose a beginning spoke closest to the valve stem hole.

a. See Figure 2-34. Each inner spoke (long head)

crosses four outer spokes (short head).

b. See Figure 2-35. Ver ify inner spoke reaches spoke

nipple and secure spoke loosely by hand. Skip every other hole and repeat lacing. Follow pattern to complete bottom row inner spokes (long head).

15. See Figure 2-36. Undo each top bundle and fan the spokes out (in a starburst pattern) around the top rim edge.

d0665x2x

Figure 2-34. Beginning Spoke: Bottom Flange Inner

d0674x2x

Figure 2-35. Completed Spokes: Bottom Flange Inner

d0667x2x

Figure 2-36. Fanning Top Flange Spokes

2006 Dyna: Chassis 2-23

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16. See Figure 2-37. Point all the top ﬂange inner spokes (long head) clockwise one at a time leaving the outer spokes (short head) resting on the rim.

NOTE Do not knock outer spokes (short head) under inner spokes (long head) or they will be trapped underneath the inner row of spokes.

17. Using the spoke alignment method discussed previously,

choose a beginning spoke closest to the valve stem hole. Start with top ﬂange inner spokes (long head) ﬁrst.

a. See Figure 2-38. Verify spoke reaches spoke nipple

and secure spoke by hand. Follow pattern to complete top ﬂange inner spokes (long head).

b. See Figure 2-39. Once you have completed the top

ﬂange of inner spokes (long head) double check for one empty hole after every third spoke.

d0668x2x

Figure 2-37. Setting Top Flange Inner Spokes

d0669x2x

Figure 2-38. Beginning Spoke: Top Flange Inner

d0670x2x

Figure 2-39. Completed Spokes: Top Flange Inner

2-24 2006 Dyna: Chassis

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d0672x2x

18. See Figure 2-40. Finish with top ﬂange outer spokes (short head). Point the top ﬂange outer spokes (short head) counterclockwise and make sure each one crosses four inner spokes before securing it to the rim.

19. See Figure 2-41. Verify spoke reaches spoke nipple and secure spoke by hand. Follow pattern to complete top ﬂange outer spokes (short head).

20. Tighten spoke nipples to 55-65

in-lbs

(6.2-7.3 Nm).

21. True the wheel. See TRUING LACED WHEEL.

d0671x2x

Figure 2-40. Beginning Spoke: Top Flange Outer

Figure 2-41. Completed Spokes: Top Flange Outer

2006 Dyna: Chassis 2-25

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WHEEL LACING: 21 IN. RIM 2.9

GENERAL

If only rim is to be replaced, tape spokes together to hold position on hub and remove spokes from rim. Install taped hub/spoke assembly to new rim and tighten spokes. Then remove tape and true wheels.

11WARNING1WARNING

Avoid using oils that attack or contribute to the deterioration of rubber materials. Use of unsuitable oils may lead to premature tire failure, which could result in death or serious injury.

CAUTION

Do not install incorrect spokes on rim. Steel laced rims use zinc plated spokes. Chrome aluminum proﬁle laced rims use chrome plated spokes.

NOTE Steel laced rims use proﬁle laced rims use

See Figure 2-42. Measure distance “A” to determine spoke length.

zinc

plated spokes. Chrome aluminum

chrome

plated spokes.

d0467x2x

Figure 2-43.

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Table 2-3. 21 In. Rim Spoke Length

Rim

Steel laced 9.42-9.46 239.3-240.3

Chrome aluminum proﬁle laced

d0759x2x

Figure 2-42. Spoke Length

IN. MM.

9.52-9.56 241.8-242.8

PROCEDURE

1. See Figure 2-43. Place the hub on table with brake disc

side (wide ﬂange) down. Insert a spoke in each hole of the

lower

row as shown below. Angle spokes clockwise.

Figure 2-44.

2. Center the rim over the hub assembly with the valve

stem hole facing upward.

3. See Figure 2-44. Using any

ﬁrst spoke into the rim hole, angled to correctly accept the spoke, on the upper half of the rim centerline.

2-26 2006 Dyna: Chassis

lower

row spoke, place the

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4. See Figure 2-45. Install the rest of lower row spokes in every fourth hole.

5. See Figure 2-46. Place the ﬁrst

upper

row spoke into the hub as shown below. Angle the spoke counterclockwise crossing four lower row spokes. The spoke must enter the hole to the right of the valve stem hole.

d0469x2x

Figure 2-45.

6. See Figure 2-47. Install the remaining nine upper row spokes into every fourth remaining hole above the rim centerline. This completes spoke installation on this side.

Figure 2-47.

7. See Figure 2-48. Tu rn rim over, brake disc side up. Place any

lower

row spoke into hub. Angle spoke clockwise

and place into rim hole angled to accept it.

d0470x2x

Figure 2-48.

Figure 2-46.

2006 Dyna: Chassis 2-27

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8. See Figure 2-49. Place the remaining nine lower row spokes, angled clockwise, into hub and rim.

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Figure 2-49.

9. See Figure 2-50. Insert any

upper

row spoke into hub and angle spoke counterclockwise into appropriate rim hole. Install remaining upper row spokes.

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Figure 2-50.

10. Tighten spoke nipples to 55-65

in-lbs

(6.2-7.3 Nm).

11. True wheel. See 2.10 TRUING LACED WHEEL.

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TRUING LACED WHEEL 2.10

GENERAL

PART NO. SPECIALTY TOOL

HD-99500-80 Wheel truing stand

HD-94681-80 Spoke wrench

The rim must be trued both laterally and radially. If new bear- ings were installed, wheels may be trued with only the bearings and center spacer installed.

LATERAL TRUING

1. Divide the wheel spokes into ten groups of four and mark the center of each group with a piece of tape. The groups should be directly across from one another and approximately 90 degrees apart. Tighten the spokes in these four groups ﬁnger tight, leaving all others loose.

2. See Figure 2-52. Install truing arbor in wheel hub and place wheel in WHEEL TRUING STAND (Part No. HD99500-80). Tighten arbor nuts so hub will turn on its bearings.

3. Lay a straightedge across hub brake disc ﬂange and one of the marked spoke groups. Measure distance “A” from the straightedge to the location shown in Figure 2-53.

NOTE

The offset dimension, distance “A”, must be as listed in Ta bl e

2-4.

Figure 8-51. Front Wheel Hub Offset Dimension

Table 2-4. Offset Dimensions

RIM TYPE RIM SIZE IN. MM.

21 1.530-1.550 38.86-39.37

Steel laced

Chrome aluminum proﬁle laced

4. If the dimension is not correct, tighten the four spokes accordingly. Use SPOKE WRENCH (Part No. HD-94681-

80). For example, If the measurement on the right rim edge side is less than it should be, loosen the two spokes attached to the hub right side and tighten the two spokes attached to the hub left side. Turn all four spokes an equal number of turns until offset dimension is correct.

Always loosen the appropriate spokes before tightening the other two. Reversing this procedure will cause the rim to become out-of-round.

5. Repeat the previous step for all four groups on the wheel.

19 1.140-1.160 28.95-29.46

17 0.620-0.640 15.75-16.26

21 1.560-1.580 39.62-40.13

19 0.890-0.910 22.68-23.19

17 0.390-0.410 9.90-10.41

NOTE

Figure 2-52. Rear Wheel Hub Offset Dimension

2006 Dyna: Chassis 2-29

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Steel laced rim

Offset:

0.390-0.410 in.

Hub on 17 in. rear spoke - all models

Offset:

0.390-0.410 in.

Hub on 17 in. rear spoke - all models

Offset: 1.140-1.160 in.

on 19 in. front spoke all but FXDWG

Chrome aluminum profile laced rim

Offset:

0.890-0.910 in.

Hub on 19 in. front spoke - all but FXDWG

Offset: 1.530-1.550 in.

Hub on 21 in. front spoke FXDWG

Offset: 1.560-1.580 in.

Hub on 21 in. front spoke FXDWG

2-30 2006 Dyna: Chassis

Figure 2-53. Laced Hub Offset Dimension

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RADIAL TRUING

1. See Figure 2-54. Adjust truing stand gauge to the rim’s tire bead seat as shown. The rim should be trued within

0.031 in. (0.79 mm).

2. Spin the rim slowly. If the rim contacts the gauge on or near a marked group of spokes, loosen the spokes in the marked group on the opposite side of the rim. Now tighten the spokes in the group where the rim makes contact. Loosen and tighten spokes an equal number of turns.

3. If the rim contacts the gauge between two marked groups, loosen the spokes in both opposite groups and tighten the spoke groups on the side of the rim that makes contact.

4. When the wheel is centered and trued, start at the valve hole and tighten the rest of the spoke nipples one turn at a time until they are snug.

5. Seat each spoke head in the hub ﬂange using a ﬂat nose punch and mallet. Then check wheel trueness again and tighten the nipples accordingly.

CAUTION

Do not tighten spokes too tight, or nipples may be drawn through rim, or hub ﬂanges may be distorted. Tighten spokes to 55-65 in-lbs (6.2-7.3 Nm). If spokes are left too loose, they will continue to loosen when wheel is put into service.

6. File or grind off ends of spokes protruding through nipples to prevent puncturing tube when tire is mounted.

NOTE After installation of front wheel, visually check the relationship of the front wheel to the fork fender bosses. The front wheel should be approximately centered between the bosses.

Figure 2-54. Truing Rim Radially

2006 Dyna: Chassis 2-31

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CAST WHEEL RUNOUT 2.11

GENERAL

The die-cast wheels should be checked for lateral and radial runout before installing a new tire or tube.

LATERAL RUNOUT

See Figure 2-55. Install arbor in the wheel hub and place wheel in the truing stand. To check rim lateral runout, place a gauge rod or dial indicator near the rim bead. If lateral runout exceeds 0.040 in. (1.02 mm), replace the wheel.

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RADIAL RUNOUT

See Figure 2-56. Check for radial runout as shown. Replace the wheel if runout exceeds 0.030 in. (0.76 mm).

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Figure 2-55. Checking Lateral Runout

Figure 2-56. Checking Radial Runout

2-32 2006 Dyna: Chassis

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CAUTION

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TIRES 2.12

GENERAL

Tires should be inspected for punctures, cuts, breaks and wear at least weekly.

11WARNING1WARNING

Replace punctured or damaged tires. In some cases, small punctures in the tread area may be repaired from within the demounted tire by a Harley-Davidson dealer. Speed should NOT exceed 50 mph (80 km/h) for the ﬁrst 24 hours after repair, and the repaired tire should NEVER be used over 80 mph (130 km/h). Failure to follow this warning could result in death or serious injury. (00015a)

Tubeless tires may be repaired in the tread area only if the puncture is 1/4 in. (6.4 mm) or smaller. All repairs must be made from inside the tire.

Acceptable repair methods include a patch and plug combination, chemical or hot vulcanizing patches or head-type plugs. When repairing tubeless tires, use TIRE SPREADER (Part No. HD-21000) to spread the tire sidewalls.

11WARNING1WARNING

Harley-Davidson tires are equipped with wear bars that run horizontally across the tread. When wear bars become visible and only 1/32 in. (0.8 mm) tread depth remains, replace tire immediately. Using a worn tire can adversely affect stability and handling, which could result in death or serious injury. Use only Dunlop HarleyDavidson replacement tires. (00090a)

It is not necessary to use tools to remove tubeless tires. Make sure beads are well lubricated before removing from rim.

If tire tools are used, take care not to damage the tire and rim sealing surfaces. Use RIM PROTECTORS (Part No. HD-01289) to protect rims.

5. Push lower bead into rim well on one side and insert tire tool underneath bead from opposite side. Pry bead over rim edge. Remove tire from rim.

It is not always necessary to completely remove tire from rim. Removing one side allows the tire to be inspected.

Figure 2-57. Starting Tire Off Rim

NOTE

11WARNING1WARNING

Harley-Davidson front and rear tires are not the same. Interchanging front and rear tires can cause tire failure, which could result in death or serious injury. (00026a)

REMOVAL

1. Remove wheel from motorcycle.

2. Let the air out of the tire.

3. Loosen both tire beads from rim ﬂange. In most cases, a bead breaker machine will be required to loosen the bead from the rim.

4. See Figure 2-57. Using tire tools (not sharp instruments), and RIM PROTECTORS (Part No. HD-01289) start upper bead over edge of rim at valve. Do not use excessive force when starting bead over rim. Bead wires may be damaged ruining the tire. Repeat all around rim until ﬁrst bead is over rim.

CLEANING AND INSPECTION

1. Clean the inside of tire and rim.

2. If rim is dirty or rusty, clean with a stiff wire brush.

3. Inspect the tire for wear.

REPLACEMENT

Always replace tires when 1/32 inch (0.8 mm) or less of tire tread remains, determined by the appearance of tire wear indicator bars. See TIRE REPLACEMENT under 1.9 TIRES

AND WHEELS.

2006 Dyna: Chassis 2-33

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INSTALLATION

11WARNING1WARNING

● Use only Harley-Davidson approved tires. Using non-

approved tires can adversely affect stability, which could result in death or serious injury. (00024a)

● Only install original equipment tire valves and valve

caps. A valve, or valve and cap combination, that is too long or too heavy can strike adjacent components and damage the valve, causing rapid tire deﬂation. Rapid tire deﬂation can cause loss of vehicle control, which could result in death or serious injury. (00281a)

NOTE

Damaged or leaking valves must be replaced.

1. See Figure 2-58. Place rubber grommet (3) on valve stem (1) with shoulder in recess of the valve stem head.

a. Insert valve stem center facing away from rim. b. Install nut (2). Tighten to 12-15 in-lbs (1.4-1.7 Nm).

5. Inﬂate the tire to recommended pressure to seat the bead. See 1.9 TIRES AND WHEELS.

6. Use BEAD EXPANDER (Part No. HD-28700) to seat beads.

d0608x2x

d0521x2x

1. Valve stem

2. Nut on outside of rim

3. Rubber

2. Thoroughly lubricate the rim ﬂanges and both beads of the tire with tire lubricant. Install RIM PROTECTORS, (Part No. HD-01289) to prevent scarring rims.

3. See Figure 2-59. Starting at the valve stem, start the ﬁrst bead into the rim well. Work the bead on as far as possible by hand. Use the tire tool to pry the remaining bead over the rim ﬂange. If tire has colored dot on sidewall, it is a balance mark and should be located next to valve stem hole.

4. See Figure 2-60. Starting 180 degrees from the valve stem, start the second bead onto the rim. Work the bead onto the rim with tire tools, working toward valve in both directions. Remove the valve core from the rim hole before prying the remaining bead over the rim ﬂange.

rommet

Figure 2-58. Valve Stem

Figure 2-59. Starting Bead on Rim

d0609x2x

Figure 2-60. Starting Second Bead on Rim

11WARNING1WARNING

Do not exceed manufacturer's recommended pressure to seat beads. Exceeding recommended bead seat pressure can cause tire rim assembly to burst, which could result in death or serious injury. (00282a)

2-34 2006 Dyna: Chassis

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CHECKING TIRE RUNOUT

Radial Runout

1. See Figure 2-61. Check runout by turning wheel on axle, measuring amount of radial displacement from a ﬁxed point near the tire.

2. Maximum tire tread runout is 0.090 in. (2.29 mm). If tire tread runout exceeds 0.090 in. (2.29 mm), remove tire from rim and check rim runout to see if rim is at fault. See

2.10 TRUING LACED WHEEL or 2.11 CAST WHEEL RUNOUT.

NOTE

Make sure bead is properly seated on rim. Deﬂate and reseat tire if necessary.

3. If rim runout is less than 0.031 in. (0.79 mm), tire is at fault and should be replaced. If rim runout is more than

0.031 in. (0.79 mm), correct by replacing cast wheel or truing laced wheel.

Lateral Runout

1. See Figure 2-62. Check runout by turning wheel on axle, measuring tread runout.

2. Maximum tire tread runout is 0.080 in. (2.03 mm). If tire tread runout exceeds 0.080 in. (2.03 mm), remove tire from rim and check rim bead runout to see if rim is at fault. See 2.10 TRUING LACED WHEEL or 2.11 CAST

WHEEL RUNOUT.

NOTE

Be sure bead is properly seated on rim. Deﬂate and reseat tire if necessary.

3. If rim bead runout is less than 0.031 in. (0.79 mm), tire is at fault and should be replaced. If rim bead runout is more than 0.031 in. (0.79 mm), correct by replacing cast wheel or truing laced wheel.

WHEEL BALANCING

Wheels must be balanced to improve handling and reduce vibration, especially at high road speeds. Cast aluminum wheels require special self-adhesive weights. Refer to Tabl e

2-5.

Table 2-5. Wheel Weights and Colors

WEIGHT

Gold yes yes no Silver no yes yes Black no no yes

1. Self adhesive wheel weights should be applied to the ﬂat surface of the rim. Be sure that application area is completely clean, dry and free of oil and grease.

1 oz.

(28 g)

0.5 oz (14 g)

0.25 oz (7 g)

Figure 2-61. Radial Tire Runout

Figure 2-62. Lateral Tire Runout

2. Remove paper backing from weight and apply 3 drops of Loctite 420 (Superbonder) to the adhesive side of the weight. Place the weight on the rim, press ﬁrmly in place and hold for 10 seconds. Full adhesive cure takes 8 hours.

NOTE

If 1 oz. (28 g) or more weight must be added at one location, split the amount so that half is applied to each side of the rim. Wheel should not be used for 8 hours to allow adhesive to cure completely.

3. In most cases, static balancing using WHEEL TRUING STAND (Part No. HD-95500-80) will produce satisfactory results. However, dynamic balancing, utilizing a wheel spinner, should be used to produce ﬁner tolerances for best high and low speed handling characteristics. Follow the instructions supplied with the balance machine you are using. Wheels should be balanced to within 0.5 oz. (14 g) at 60 MPH (97 km/h). The maximum permissible weight to accomplish balance is 3.5 oz. (99 g) total.

2006 Dyna: Chassis 2-35

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VEHICLE ALIGNMENT 2.13

INSPECTION

11WARNING1WARNING

Check vehicle alignment according to following procedures. Incorrect alignment can adversely affect stability and handling, which could result in death or serious injury. (00287a)

1. Verify wheels are true to speciﬁcations. See 2.10 TRUING

LACED WHEEL or 2.11 CAST WHEEL RUNOUT.

2. Check steering head bearing adjustment and adjust if necessary. See 1.17 STEERING HEAD BEARINGS.

3. See Figure 2-64. To ensure accurate measurements, obtain a piece of 1/8 in. (3.2 mm) aluminum welding rod 11 in. (280 mm) long. Grind one end down to a blunt point. With a pliers, bend the rod 90 degrees as shown. Place a snug ﬁtting grommet on the rod to act as a slide measurement indicator.

4. See Figure 2-63. With the blunt point of the alignment tool inserted in the rear fork pilot hole, slide the rubber grommet along the tool until it is aligned with the center of the axle as shown. Repeat for the other side of the motorcycle.

7477

d0482x2x

Figure 2-63. Measuring Alignment

Grommet

1.25 in.

(32 mm)

10.0 in.

(254 mm)

Figure 2-64. Alignment Tool

2-36 2006 Dyna: Chassis

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Chassis

Powertrain

Distance ‘A’ must be equal

Rear fork

hole

Rear axle

center

Correct by adjusting belt adjusters

d0481x2x

5. See Figure 2-65. The measurement between the center of the rear axle and the rear fork hole must be equal to within 1/32 in (0.8 mm). on both sides of the motorcycle. If it is not, adjust the rear wheel with the axle adjusters to accomplish the equal measurement. It is extremely important that this adjustment be made as accurately as possible in order to make the remaining adjustments accurate.

6. Raise the rear of the motorcycle so that the rear wheel spins freely. Do this by placing a center stand or blocking under the frame.

7. See Figure 2-66. Remove the bolt (2) which attaches the top stabilizer link (1) to the engine mounting bracket.

8. Position front wheel so brake disc is vertical using an inclinometer. If possible, use a digital inclinometer for the best accuracy.

NOTES

● The exhaust system must be in place while performing

the following steps.

● Motorcycle must be upright and level before performing

this procedure.

Figure 2-65. Rear Wheel Misaligned

2006 Dyna: Chassis 2-37

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CAUTION

The Dyna Glide stabilizer link should only be loosened/ adjusted on one end. There is one end that has threads showing. Adjust this end only. Do not loosen/adjust the other end or the isolator will tear.

NOTE There should be 0.25 in. (6.4 mm) minimum clearance between the fuel tank tunnel and the head of the left stabilizer link mounting bolt.

9. Loosen jam nut (3) on stabilizer link. Adjust the stabilizer

so that the bolt removed in step 7 can be reinstalled without pushing the engine to the right or left. Tighten jam nut.

10. Check the rear brake disc with the inclinometer to ensure

that it is parallel to the front brake disc.

IF THE ABOVE STEPS DO NOT ALIGN VEHICLE:

11. If the rear brake disc is not parallel to the front brake disc,

adjust the top stabilizer link until the rear brake is parallel to within 1 degree of the front brake disc’s position.

12. If you cannot adjust the front and rear brake discs to

within 1 degree, inspect the frame, front fork and/or rear fork for damage.

12137

1. Top stabilizer link

2. Bolt

3. Jam nut

4. Adjusting stud (nut)

Figure 2-66. Top Stabilizer

11WARNING1WARNING

To prevent damage to fuel tank and possible ﬁre or explosion, which could cause death or serious injury, maintain clearance speciﬁed in service manual between fuel tank and head of left stabilizing link mounting bolt. (00262a)

13. If you have to adjust the top stabilizer link more than ﬁve

full turns to bring the brake discs to speciﬁcation, again inspect the frame, front fork and/or rear fork for damage.

14. Tighten the stabilizer jam nut (3).

NOTE If the stabilizer link has been adjusted more than ﬁve full turns, the vehicle’s vibration will very likely have reached an unacceptable level. Adjust the vehicle’s vibration level as follows:

15. Be sure the transmission is in neutral.

16. Loosen, but do not remove, ALL the mounting bolts on

the engine isolators and start the engine. Let the engine run for approximately 5 seconds. This will center the mounts on the frame and power train assembly.

17. Tighten isolator mounting bolts to 25 ft-lbs (33.9 Nm).

2-38 2006 Dyna: Chassis

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1. Single disc master cylinder

2. Bore stamp size

FRONT BRAKE MASTER CYLINDER 2.14

GENERAL

11WARNING1WARNING

Do not use parts from single caliper repair kits (9/16 inch bore) on dual caliper models. Likewise, do not use parts from dual caliper repair kits (11/16 inch bore) on single caliper models. Using incorrect parts can cause brake failure, which could result in death or serious injury. (00278a)

See Figure 2-67. Master cylinders designed for single disc (one caliper) operation have a 9/16 inch (14.3 mm) bore. The bore size is stamped on the master cylinder assembly inboard of the handlebar clamp bracket.

REMOVAL/DISASSEMBLY

1. Open bleeder nipple cap on front brake caliper. Install end of a length of clear plastic tubing over caliper bleeder valve, while placing free end in a suitable container. Open bleeder valve about 1/2-turn. Pump brake hand lever to drain brake ﬂuid. Close bleeder valve.

Figure 2-67. Bore Size

CAUTION

Damaged banjo bolt surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing brake line components.

2. Remove bolt and two steel/rubber washers to disconnect ﬁtting of hydraulic brake line from master cylinder. Discard washers.

CAUTION

Do not remove or install the master cylinder assembly without ﬁrst positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a)

2006 Dyna: Chassis 2-39

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1. Lubricant

2. Wiper

3. Piston cap

4. O-ring

5. Piston

6. Primary cup

7. Spring

8. Handlebar clamp

9. T27 TORX screw and washer (2)

10. Gasket

11. Cover

12. Site glass

13. Screw (2)

14. Master cylinder reservoir

15. Pivot pin

16. Bushing

17. Brake hand lever

18. Retaining ring

Flat side

Service parts kit contains items 1-7.

● 9/16 in. bore - Part No. 45006-96C

O-ring groove

Shoulder

Figure 2-68. Front Brake Master Cylinder

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2-40 2006 Dyna: Chassis

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1. Groove

2. 5/32 in. (4mm) thick cardboard insert

3. See Figure 2-69. Place the cardboard insert between the brake lever and lever bracket.

4. See Figure 2-68. Remove the two T27 TORX screws with ﬂat washers (9) to detach the handlebar clamp (8) from the master cylinder reservoir (14).

11WARNING1WARNING

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

5. Remove retaining ring (18) from pivot pin groove at bottom of master cylinder bracket.

6. Remove pivot pin (15) and brake hand lever (17).

7. Carefully remove wiper (2) with pick or similar tool.

8. Remove piston cap (3).

9. Remove piston (5) with O-ring (4) and primary cup (6).

10. Remove spring (7).

CAUTION

Do NOT allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage. (00205b)

11. Remove both screws (13), cover (11) and the cover gasket (10).

Figure 2-69. Cardboard Insert

2006 Dyna: Chassis 2-41

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CLEANING AND INSPECTION

11WARNING1WARNING

1. Always reassemble the master cylinder using new parts from the correct repair kit (9/16 inch bore- HD Part No. 45006-96C.

11WARNING1WARNING

Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause brake failure, which could result in death or serious injury. (00291a)

2. Clean all parts with denatured alcohol or. Do not contaminate with mineral oil or other solvents. Wipe dry with a clean, lint free cloth. Blow out drilled passages and bore with a clean air supply. Do not use a wire or similar instrument to clean drilled passages in bottom of reservoir.

3. Carefully inspect all parts for wear or damage and replace as necessary.

4. Inspect the piston bore in the master cylinder housing for scoring, pitting or corrosion. Replace the housing if any of these conditions are found.

5. Inspect the outlet port that mates with the brake line ﬁtting. As a critical sealing surface, replace the housing if any scratches, dents or other damage is noted.

6. Inspect the cover gasket for cuts, tears or general deterioration. Replace as necessary.

ASSEMBLY/INSTALLATION

1. See Figure 2-68. Fit O-ring (4) into groove at front of piston (5) (pin side).

2. Fit primary cup (6) over lip at back of piston so that closed side (smaller OD) contacts shoulder.

3. Coat piston bore of housing with special lubricant (1) supplied in the service parts kit. Also apply the lubricant to OD of installed O-ring (4) and primary cup (6).

4. Insert spring (7) into master cylinder bore so that it seats against the recess at bottom.

5. Slide piston over spring.

6. Fit wiper (2) over piston cap (3) so that the ﬂat side of wiper contacts cap shoulder.

7. Fit piston cap over piston pin (5).

8. Press down on wiper until it contacts the counterbore. Larger OD of wiper must be completely seated in groove on outlet side of piston bore.

9. Install the cover (11) with gasket (10) on the master cylinder reservoir. Install two screws (13) to fasten the cover to the reservoir, but do not tighten at this time.

10. Align hole in brake hand lever (17) with hole in master cylinder bracket. From the top of the assembly, slide pivot pin (15) through bracket and hand lever.

11WARNING1WARNING

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

11. Install retaining ring (18) in pivot pin groove. Verify that retaining ring is completely seated in groove.

CAUTION

2-42 2006 Dyna: Chassis