Dyna Models Service Manual

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2004 DYNA MODELS

SERVICE MANUAL

Part Number 99481-04

Section 1: Maintenance Section 2: Chassis Section 3: Engine Section 4: Fuel System Section 5: Starter Section 6: Drive Section 7: Transmission Section 8: Electrical Section 9: Fuel Injection Appendix

ELECTRICAL DIAGNOSTICS

Part Number 99495-04

Section 1: Starting & Charging Section 2: Instruments Section 3: TSM & TSSM Section 4: Engine Management (Carbureted) Section 5: Engine Management (EFI) Section 6: Wiring

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1-2 Edit Me: Printed August 20, 2003 3:57 pm

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.5 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

1.7 Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

1.8 Brake Pads and Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

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

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

1.11 Primary Chaincase Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

1.12 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

1.13 Transmission Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

1.14 Rear Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1.15 Rear Belt and Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

1.16 Suspension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

1.17 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

1.18 Front Fork Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

1.19 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41

1.20 Air Cleaner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

1.21 Cable and Chassis Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

1.22 Throttle Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

1.23 Enrichener: Carbureted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

1.24 Idle Speed/Ignition Timing: Carbureted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

1.25 Fuel Supply Valve Filter: Carbureted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48

1.26 Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

1.27 Headlamp Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

1.28 Critical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

1.29 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

1.30 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56

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11WARNING1WARNING

GENERAL 1.1

SERVICING A NEW MOTORCYCLE

11WARNING1WARNING

Always follow the listed service and maintenance recommendations, since they affect the safe operation of the motorcycle and the personal welfare of the rider. Failure to follow recommendations could result in death or serious injury.

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 2500 mile (4000 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.

SHOP PRACTICES

Repair Notes

NOTE

●

General maintenance practices are given in this section. 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 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.

2004 Dyna: Maintenance 1-1

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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-

1-2 2004 Dyna: Maintenance

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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.

2004 Dyna: Maintenance 1-3

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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 insulation; 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.

1-4 2004 Dyna: Maintenance

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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 leaded or unleaded gasoline (91 pump octane or higher). Pump octane is the octane number usually shown on the gas pump.

GASOLINE BLENDS

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.

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

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

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.

●

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.

Yo u 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.

2004 Dyna: Maintenance 1-5

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MAINTENANCE SCHEDULE 1.3

4 5 0 0 0

7 2 0 0 0

5 0 0 0 0

8 0 0 0 0

MAINTENANCE TASK

AND SERVICE DATA

Engine oil (*)

Oil level:

Dipstick level depends on vehicle temperature. (1.4 ENGINE OIL AND FILTER)

Engine oil ﬁlter (*)

Filter tightening:

Hand tighten oil ﬁlter 1/2 to 3/4 turn after gasket surface contacts ﬁlter mounting surface.

(1.4 ENGINE OIL AND FILTER)

Battery (*)

(1.5 BATTERY MAINTENANCE)

Brake ﬂuid level and condition

Brake ﬂuid type:

D.O.T. 5 SILICONE BRAKE FLUID

(1.6 BRAKES)

Brake pads and discs for wear

Minimum pad thickness:

0.04 in. (1.02 mm)

Maximum brake disc lateral runout:

0.008 in. (0.2 mm)

(1.8 BRAKE PADS AND DISCS)

Tire pressure and inspect tire for wear/damage (*)

(1.9 TIRES AND WHEELS)

8 0 0 0

1 6 0 0 0

I P R E

IRRRRRRRRRRR

R RRRRRRRRRR

I IIIIIIIIII

IIIIIIIIIIII

2 4 0 0 0

0 0

3 2 0 0 0

0 0

4 0 0 0 0

0 0 0

4 8 0 0 0

0 0 0

5 6 0 0 0

0 0 0 0

6 4 0 0 0

Table Code: A

- Adjust.

- Inspect, and if necessary, correct, adjust, clean or replace.

- Lubricate with speciﬁed lubricant.

- Replace or change.

1-6 2004 Dyna: Maintenance

- Tighten to proper torque.

-Perform.

- Disassemble, lubricate and inspect.

(*)- Also perform prior to storage or annually.

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MAINTENANCE TASK

AND SERVICE DATA

Wheel spoke tightness

Wheel spoke nipple torque:

40-50

in-lbs

(4.5-5.6 Nm)

(1.9 TIRES AND WHEELS)

Primary chain adjustment (*)

Deﬂection:

Deﬂection depends upon vehicle temperature.

(1.10 PRIMARY CHAIN)

Primary chain lubricant

Lubricant level:

Visible between clutch and chaincase inner wall with vehicle upright, 26 oz (768.9 ml).

Lubricant type:

Part No. 99887-84 (quart) or 99886-84 (gallon)

(1.11 PRIMARY CHAINCASE LUBRICANT)

Clutch adjustment

Hand lever free play:

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

(1.12 CLUTCH)

Transmission lubricant (*)

Lubricant level:

Bottom edge of FULL mark on dipstick with vehicle upright.

Lubricant type:

Part No. 99892-84 (quart), 99891-84 (gal), 98853-96 (case/qts) or 98852-96 (case/ gals).

Drain plug:

14-21 ft-lbs (19.0-28.5 Nm)

(1.13 TRANSMISSION LUBRICANT)

I P R E

IIIIIIIIII

RRRRRRRRRR

IIIIIIIIII

RRRRRRRRRR

2 4 0 0 0

0 0

3 2 0 0 0

0 0

4 0 0 0 0

0 0 0

4 8 0 0 0

0 0 0

5 6 0 0 0

0 0 0 0

6 4 0 0 0

5 0 0 0 M

7 2 0 0 0

5 0 0 0 0

8 0 0 0 0

Table Code: A

- Adjust.

- Inspect, and if necessary, correct, adjust, clean or replace.

- Lubricate with speciﬁed lubricant.

- Replace or change.

- Tighten to proper torque.

-Perform.

- Disassemble, lubricate and inspect.

(*)- Also perform prior to storage or annually.

2004 Dyna: Maintenance 1-7

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MAINTENANCE TASK

AND SERVICE DATA

Rear belt deﬂection inspection (*)

Deﬂection:

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

Specialty tool:

Part No. HD-35381

(1.14 REAR BELT DEFLECTION)

Rear belt and sprocket (*)

(1.15 REAR BELT AND SPROCKETS)

Steering head bearing adjustment

(1.17 STEERING HEAD BEARINGS)

Lubricate steering head bearings Front fork oil

(1.18 FRONT FORK OIL)

Spark plugs (*)

Plug type:

No. 6R12

Plug gap:

0.038-0.043 (0.97-1.09 mm)

Plug torque:

11-18 ft-lbs (14.9-24.4 Nm)

(1.19 SPARK PLUGS)

Air cleaner ﬁlter (*)

Cover screw torque:

36-60

in-lbs

(4.1-6.8 Nm)

(1.20 AIR CLEANER FILTER)

Lubricate controls (*)

Front brake hand lever, clutch hand lever, throttle control cables, clutch control cable, rear brake pedal and jiffy stand

(1.21 CABLE AND CHASSIS LUBRICATION)

1 0 0 0 M

I P R E

IIIIIIIIII

IRIRIRIRIR

IIIIIIIIII

LLLLLLLLLL

A D A A

0 0 0

5 6 0 0 0

0 0 0 0

6 4 0 0 0

5 0 0 0

7 2 0 0 0

5 0 0 0 0

8 0 0 0 0

Table Code: A

- Adjust.

- Inspect, and if necessary, correct, adjust, clean or replace.

- Lubricate with speciﬁed lubricant.

- Replace or change.

1-8 2004 Dyna: Maintenance

- Tighten to proper torque.

-Perform.

- Disassemble, lubricate and inspect.

(*)- Also perform prior to storage or annually.

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MAINTENANCE TASK

AND SERVICE DATA

Operation of throttle and enrichener controls

(1.22 THROTTLE CABLES)

Engine idle speed

Idle speed:

950-1050 RPM

(1.24 IDLE SPEED/IGNITION TIMING: CARBURETED)

Fuel supply valve ﬁlter screen

Filter hex ﬁtting torque:

15-20 ft-lbs (20.3-27.1 Nm)

(1.25 FUEL SUPPLY VALVE FILTER: CARBURETED)

Fuel supply valve, hoses and ﬁttings for leaks (*)

(1.25 FUEL SUPPLY VALVE FILTER: CARBURETED)

Replace rear fork bearings

(2.23 REAR FORK)

Check oil and brake lines for leaks Engine mounts

(1.26 ENGINE MOUNTS)

Operation of all electrical equipment and switches (*) All critical fasteners except engine head bolts

(1.28 CRITICAL FASTENERS)

Inspect windshield grommets Road test

I P R E

IIIIIIIIII

T T T T T

XXXXXXXXXX

I I I I

0 0

4 0 0 0 0

0 0 0

4 8 0 0 0

0 0 0

5 6 0 0 0

0 0 0 0

6 4 0 0 0

5 0 0 0 M

7 2 0 0 0

5 0 0 0 0

8 0 0 0 0

Table Code: A

- Adjust.

- Inspect, and if necessary, correct, adjust, clean or replace.

- Lubricate with speciﬁed lubricant.

- Replace or change.

- Tighten to proper torque.

-Perform.

- Disassemble, lubricate and inspect.

(*)- Also perform prior to storage or annually.

2004 Dyna: Maintenance 1-9

Page 16

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NOTES

1-10 2004 Dyna: Maintenance

Page 17

6626

HOME

ENGINE OIL AND FILTER 1.4

CHECKING AND ADDING OIL

See Figure 1-1. Check engine oil level:

As part of the pre-ride inspection.

●

At every scheduled service interval.

●

Type of Oil

Refer to Table 1-1. 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, CF-4, CG-4 and CH-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

See Figure 1-2. For preride inspection with motorcycle lean- ing on jiffy stand on level ground, oil should register on dipstick in the range between lower arrow (1) and midway point (2) when engine is cold.

If oil level is at or below lower arrow, add only enough oil to bring the level between the two arrows (2) on the dipstick. Do

NOT

add oil to FULL mark (3) on a cold engine.

d0386x1x

Figure 1-1. Checking Oil Level

NOTE

For cold check level do not exceed

this point when ﬁlling with oil.

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, check oil level by inserting dipstick completely into oil pan filler neck.

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

1. Lower arrow (add oil)

2. Cold check level

3. Upper arrow (hot check level)

Figure 1-2. Engine Oil Dipstick

Table 1-1. Recommended Oil Grades

HARLEY-

DAVIDSON TYPE

VISCOSITY

HARLEY-

DAVIDSON

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

COLD WEATHER STARTS BELOW

50°F

2004 Dyna: Maintenance 1-11

Page 18

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CHANGING OIL AND FILTER

PART NO.

HD-42311 or

Oil ﬁlter wrench

HD-44067

Change engine oil and ﬁlter:

●

At the 1000 mile (1600 km) service interval. At every 5000 mile (8000 km) service interval thereafter.

●

When storing or removing the motorcycle for the season.

If the motorcycle is ridden hard, under dusty conditions,

●

or in cold weather, the oil and ﬁlter should be changed more often.

●

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

All Dyna Glides come equipped from the factory with a

●

premium 10 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. Remove the oil ﬁller plug/dipstick by pulling steadily while moving plug back and forth.

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

SPECIALTY TOOL

NOTES

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

CAUTION

See Figure 1-4. Use Harley-Davidson OIL FILTER WRENCH for ﬁlter removal. This tool can prevent damage to crankshaft position sensor and/or sensor cable.

4. Remove the oil ﬁlter using the OIL FILTER 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

new

ﬁlter. Hand tighten oil ﬁlter 1/2

new

oil ﬁlter with

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 Table 1-1.

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.

NOTE 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.

Figure 1-4. Oil Filter Wrench

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

d0384x1x

Figure 1-5. Lubing New Oil Filter

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.

1-12 2004 Dyna: Maintenance

Page 19

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d0424x1x

1. Warning label

2. Positive terminal cover

BATTERY MAINTENANCE 1.5

GENERAL

11WARNING1WARNING

See Figure 1-6. 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

See Figure 1-7. Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Always 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.

Figure 1-6. Battery

Table 1-2. 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.

d0425x1x

Contents

are Corrosive.

Safety Glasses.

Wear

SOLUTION

Contents

are Explosive.

NOTE

See 8.14 BATTERY for charging and testing information.

Keep

Flames Away.

Read

Instructions.

Keep Away

From Children.

Figure 1-7. Battery Warning Label

2004 Dyna: Maintenance 1-13

Page 20

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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 rear fastener (13).

3. Loosen, but do not remove upper rear fastener (14). Battery tray (5) will pivot down.

4. Remove top cover assembly (10).

5. Remove side cover (1) if present.

6. With only enough movement to expose negative battery terminal (3), pull battery (2) from tray.

7. Unthread and remove battery negative cable (4) from negative battery terminal.

8. Move battery terminal cover (15) and unbolt and remove battery positive cable (11) from positive (+) battery terminal (12).

9. Lift battery from tray.

10. To remove battery tray: a. Remove upper rear bolt. b. Lift battery tray so battery tray mounting tab (6) dis-

engages from battery tray mounting slot (8).

INSTALLATION AND CONNECTION

d0736x8x

1. Side cover

2. Battery

3. Negative battery terminal

4. Battery negative cable

5. Battery tray

6. Battery tray mounting tab

7. Bushing

8. Battery tray mounting slot

9. Frame

10.Top cover assembly

11.Battery positive cable

12.Positive battery terminal

13.Lower rear fastener

14.Upper rear fastener

15.Battery terminal cover

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.

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)

1. See Figure 1-8. Reinstall battery tray (5) if removed. a. Insert battery tray mounting tab (6) into battery tray

mounting slot (8).

b. Install but do not tighten upper rear fastener (14).

Figure 1-8. Battery Assembly

1-14 2004 Dyna: Maintenance

Page 21

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Effect of temperature on

battery self-discharge rate

Months of stand

C a p a c

i t

d0426x1x

NOTE

Be sure battery (2) is fully charged before installation.

2. With battery terminals facing primary cover, insert fastener through battery positive cable (11) into threaded hole of battery positive (+) terminal (12). Tighten fastener to 60-96 cover (15) over positive battery terminal.

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

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

5. Place battery into the battery tray.

6. Install battery side cover (1) if present. Make sure the bottom of the cover’s outboard side is properly seated inboard of the retaining lip on the base of the battery tray.

7. Install top cover assembly (10) over side cover and battery.

8. Tighten upper rear fastener (14) to 120-144

16.3 Nm).

9. Install and tighten lower rear mounting fastener (13) to 120-144

in-lbs

(6.8-10.9 Nm). Place battery terminal

in-lbs

(6.8-10.9 Nm).

in-lbs

(13.6-16.3 Nm).

in-lbs

(13.6-

11WARNING1WARNING

Figure 1-9. Battery Self-Discharge Rate

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)

10. Install seat.

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.

2004 Dyna: Maintenance 1-15

Page 22

HOME

STORAGE

11WARNING1WARNING

Store the battery out of the reach of children. Inadequate safety precautions could result in death or serious injury.

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 8.14 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).

NOTE The BATTERY TENDER PLUS AUTOMATIC BATTERY CHARGER (Part No. 99863-93TA) 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 8.14 BATTERY.

1-16 2004 Dyna: Maintenance

Page 23

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d0678x1x

Fluid level should be

1/8 in. (3.2 mm) below

gasket surface

d0597x1x

Fluid level should be

1/8 in. (3.2 mm) below

gasket surface

BRAKES 1.6

FLUID INSPECTION

Check brake ﬂuid reservoir level and condition:

At the 1000 mile (1600 km) service interval.

●

At every 5000 mile (8000 km) service interval thereafter.

●

When storing or removing the motorcycle for the season. Also, check for ﬂuid leaks at every service interval.

●

1CAUTION

Direct contact of D.O.T. 5 brake ﬂuid with eyes can cause eye irritation, swelling, and redness. 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. 5 brake ﬂuid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a)

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

Figure 1-10. Rear Brake Master Cylinder Reservoir

CAUTION

To prevent dirt from entering the master cylinder reservoir, thoroughly clean the cover before removal.

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

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

in-lbs

(0.7-0.9 Nm).

11WARNING1WARNING

After completing repairs or bleeding the system, always test motorcycle brakes at low speed. If brakes are not operating properly or braking efﬁciency is poor, testing at high speeds could result in death or serious injury.

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. 5 SILICONE BRAKE FLUID. See 1.7 BLEED-

ING BRAKES.

Figure 1-11. Front Brake Master Cylinder Reservoir

2004 Dyna: Maintenance 1-17

Page 24

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 pushrod (3) in rear brake master cylinder (1), and locked in place with jam nut (4). Loosen jam nut.

11WARNING1WARNING

Do not lengthen linkage beyond point that exposes six threads outside of the jam nut or insufﬁcient thread engagement between push rod and brake rod could cause linkage to come apart. This would result in a loss of the rear brake, which could lead to an accident resulting in death or serious injury.

2. Using an open-end wrench on the pushrod 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. Pushrod

4. Jam nut

5. Brake rod

Figure 1-12. Rear Brake Pedal Height

1-18 2004 Dyna: Maintenance

Page 25

HOME

11WARNING1WARNING

7400

7425

BLEEDING BRAKES 1.7

GENERAL

1CAUTION

Check brake ﬂuid level and condition:

●

At the 1000 mile (1600 km) service interval.

At every 5000 mile (8000 km) service interval thereafter.

●

When storing or removing the motorcycle for the season.

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

Figure 1-13. Front Brake Bleeder Valve

PROCEDURE

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. 5 SILICONE BRAKE FLUID to master cylinder reservoir. Fluid level should be 1/8 in. (3.2 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).

2004 Dyna: Maintenance 1-19

Page 26

HOME

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

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.

1-20 2004 Dyna: Maintenance

7425

Figure 1-16. Pad Retaining Pins

(Rear Caliper Shown)

Page 27

HOME

11WARNING1WARNING

d0558a2x

1. Two tabs on backing plate

2. Single square tab on backing plate

3. Curved portion

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)

CAUTION

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

11. Inspect pad pins for grooving and wear. Measure the pad

12. Install

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

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.

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.

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).

Figure 1-17. Brake Pad Orientation

Figure 1-18. Front Brake Caliper

(Left Side Shown)

Whenever new pads are installed, BEFORE moving motorcycle, you must pump brake ﬂuid until the pistons push the pads against the brake disc. If you don’t pump ﬂuid pressure up again, the brakes will not be available to stop the motorcycle which could result in death or serious injury.

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. 5 SILICONE BRAKE FLUID. Install master cylinder reservoir cap. Tighten reservoir cap screws to 6-8

16. Install right saddlebag if necessary.

11WARNING1WARNING

in-lbs

(0.7-0.9 Nm).

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

2004 Dyna: Maintenance 1-21

Page 28

HOME

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.

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.

●

On the right side of the vehicle, the pad with two tabs (1) installs on the inboard side of the caliper.

On the left side of the vehicle, the pad with two tabs (1),

●

installs on the outboard side of the caliper.

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 1-19. On models with dual front calipers,

check alignment of brake discs to calipers. Loosen axle pinch bolt nuts. Tighten axle nut to proper torque. Insert a 7/16 in. drill bit (1) through hole in front axle as far as it will go. Contact point (2) must have edge of drill bit touching the edge of fork leg. See 2.4 FRONT WHEEL.

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

bleeder valve facing upwards.

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

into top hole on fork leg.

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

bottom hole on fork leg. Tighten bottom mounting bolt to 28-38 ft-lbs (38.51.5 Nm).

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

(38.51.5 Nm).

f. Final tighten both pad pins to 180-200

22.6 Nm).

g. On models with dual front calipers, tighten pinch bolt

nuts while holding slider against 7/16 drill bit if necessary. See 2.4 FRONT WHEEL. Remove drill bit.

in-lbs

(20.3-

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. 5 SILICONE 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.

7472

1. 7/16 Drill bit

2. Contact point

new

pads to become conditioned to the brake

Figure 1-19. Dual Caliper Alignment

1-22 2004 Dyna: Maintenance

Page 29

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o0250x0x

00249x0x

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 nonapproved 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. Tire 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 Table 1-3.

Table 1-3. 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

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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

Inspect vehicles with wheel spokes:

● At the 5000 mile (8000 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

1. Raise motorcycle wheel off the ground.

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 40-50 in-lbs (4.5-5.6 Nm). If more than a few spokes are loose, true the entire wheel following procedure under 2.10 TRUING LACED WHEEL.

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d0162a3x

1. Primary chaincase cover

2. Gasket

3. Primary chain inspection cover (FXDWG)

4. Primary chain inspection cover (all except FXDWG)

5. Short screws (2)

6. Long screws (2)

7. Foot shifter lever (all except FXDWG)

8. Washer (all except FXDWG)

9. Screw (all except FXDWG)

PRIMARY CHAIN 1.10

INSPECTION

Check primary chain tension:

● At the 1000 mile (1600 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

11WARNING1WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable ﬁrst) before proceeding. (00048a)

11WARNING1WARNING

1. Set motorcycle upright and level.

2. See Figure 1-21. On all models except FXDWG, remove screw (9), washer (8) and foot shifter lever (7).

3. Remove two short screws (5), two long screws (6) and primary chain inspection cover (3 or 4).

CAUTION

Adjust the primary chain at the tightest spot in the chain. Do not adjust chain tighter than speciﬁed play. Running chains too tight will result in excessive wear.

4. Check the primary chain tension. Push on the upper strand on the chain to verify that it has free movement midway between the engine compensating sprocket in the front and the clutch sprocket in the rear.

a. With the engine cold, upward (not total) freeplay in

upper strand should be 5/8-7/8 in. (15.9-22.3 mm).

b. With the engine hot, upward (not total) freeplay in

upper strand should be 3/8-5/8 in. (9.5-15.9 mm).

5. If freeplay adjustment is required, see Figure 1-22. a. Loosen, but do not remove, the center bolt nut (1). b. Move the shoe assembly (2) up or down to obtain

the speciﬁed freeplay.

c. Tighten center bolt nut to 21-29 ft-lbs (28.5-

39.3 Nm). Replace the primary chain (3) if it is worn to the point where it cannot be properly adjusted.

Figure 1-21. Inspection Cover

d0594x2x

1. Center bolt nut @ 21-29 ft-lbs (28.5-39.3 Nm)

2. Shoe assembly

3. Primary chain

Figure 1-22. Primary Chain Adjustment

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6. All models except FXDWG: see Figure 1-23. Inspect two o-rings (4) in grooves on end of shift lever sleeve (5). Replace if damaged or worn.

7. See Figure 1-21. Install inspection cover (3 or 4) and new gasket (2). Tighten both pairs of cover fasteners (5,

6) to 84-108 in-lbs (9.5-12.2 Nm).

8. On all models except FXDWG, install foot shifter lever (7), washer (8) and screw (9). Tighten screw to 96-120 in-lbs (10.8-13.5 Nm).

1. Shifter rod

2. Shift lever

3. Wave washer

4. Sleeve o-ring (3)

5. Shift lever sleeve

6. Screw

7. Washer

8. Foot shifter lever

Figure 1-23. Shift Lever Assembly (All But FXDWG)

O-rings fit in

these grooves

d0693x3x

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d0385b1x

d0161x1x

1. TORX screw with captive washer

2. Clutch inspection cover

3. Quad ring

s0549x1x

PRIMARY CHAINCASE LUBRICANT 1.11

CHANGING LUBRICANT

Replace primary chaincase lubricant:

● At the 1000 mile (1600 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

1. See Figure 1-24. Remove drain plug at bottom of 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. Inspect drain plug O-ring for cuts, tears or signs of deterioration. Replace as necessary.

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

5. See Figure 1-25. Remove ﬁve TORX screws with captive washers (1) to detach clutch inspection cover (2) from primary chaincase cover.

6. Remove the quad ring (3) from the groove in the chaincase cover. Wipe oil from quad ring, groove in chaincase cover and mounting surface.

Figure 1-24. Removing Chaincase Drain Plug

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)

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. Pour 26 oz (768.9 ml) of primary chaincase lubricant in through the clutch inspection cover opening. See Figure

1-26. The primary chaincase lubricant level is acceptable

when lubricant is visible in the bottom of the chaincase with the motorcycle standing upright (not resting on jiffy stand).

NOTE

● Use only Harley-Davidson PRIMARY CHAINCASE

LUBRICANT, Part No. 99887-84 (quart) or Part No. 99886-84 (gallon).

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

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

Figure 1-25. Clutch Cover

Figure 1-26. Lubricant Level With Motorcycle Upright

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CAUTION

If lubricant is not thoroughly removed from both the oring and groove, compression of the o-ring during installation of the clutch inspection cover can cause lubricant to be squeezed to the outboard side of the ring groove, resulting in some temporary weepage around the inspection cover. (00201a)

8. Install clutch inspection cover. a. Inspect quad ring for tears or damage. Replace as

required.

b. Thoroughly wipe all lubricant from quad ring, cover

mounting surface and groove in chaincase. c. Place quad ring in chaincase. d. Attach clutch inspection cover using ﬁve TORX

screws with captive washers. Tighten to 84-108 in-

lbs (9.5-12.2 Nm). Follow torque sequence shown in

Figure 1-27.

CAUTION

Do not move or shift cover while installing TORX fasteners. Movement will cause the quad ring to become displaced. This may result in leakage around the inspection cover.

d0341x1x

Figure 1-27. Clutch Cover Torque Sequence

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d0599x1x

1. Rubber boot

2. Cable adjuster

3. Jam nut

4. Cable end

d0383b1x

1. Locknut

2. Clutch adjuster screw

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

d0382a1x

1. Clutch cable

2. Cable ferrule

3. Clutch lever bracket

CLUTCH 1.12

ADJUSTMENT

Check clutch adjustment:

● At the 1000 mile (1600 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

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.

Figure 1-28. Clutch Cable Adjuster

3. See Figure 1-28. Add freeplay to cable.

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

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

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

4. See Figure 1-29. 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.

5. 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.

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

7. Check freeplay.

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

b. See Figure 1-30. Pull clutch cable ferrule (2) away

8. 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.

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

of freeplay at clutch hand lever.

eliminated at hand lever.

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.

Figure 1-29. Clutch Adjuster Screw

Figure 1-30. Clutch Hand Lever

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CAUTION

9. Install clutch inspection cover. a. Remove quad ring from groove in chaincase cover. b. Inspect quad ring for tears or damage. Replace as

required.

c. Thoroughly wipe all lubricant from quad ring, cover

mounting surface and groove in chaincase. d. Place quad ring in chaincase. e. Attach clutch inspection cover using ﬁve TORX

screws with captive washers. Tighten to 84-108 in-

lbs (9.5-12.2 Nm). Follow torque sequence shown in

Figure 1-31.

CAUTION

Do not move or shift cover while installing TORX fasteners. Movement will cause the quad ring to become displaced. This may result in leakage around the inspection cover.

d0341x1x

Figure 1-31. Clutch Cover Torque Sequence

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d0387x1x

1. Engine oil drain plug

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

Front of motorcycle

d0442x3x

d0163x1x

1. Full mark

2. O-ring

TRANSMISSION LUBRICANT 1.13

CHANGING LUBRICANT

Replace transmission lubricant:

● At the 1000 mile (1600 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

1. See Figure 1-32. Remove transmission ﬁller plug.

2. See Figure 1-33. 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.

Figure 1-32. Transmission Lubricant Check/Fill

4. Fill the transmission with 20-24 oz. (591.5-709.8 ml) of

5. Check lubricant level.

6. Install ﬁller plug/dipstick.

11WARNING1WARNING

Harley-Davidson TRANSMISSION LUBRICANT, Part No. 99892-84 (qt) or 99891-84 (gal).

a. Place motorcycle in a level, upright position.

b. Place dipstick inside ﬁll hole and remove. Dipstick

should rest on lip of ﬁller. Do not screw in tight.

c. See Figure 1-34. Lubricant level should be at the

F(ULL) mark on dipstick when removed.

a. Check O-ring on dipstick for tears or damage.

Replace as required. Wipe any foreign material from plug.

b. Install ﬁller plug/dipstick and tighten to 25-75 in-lbs

(2.8-8.5 Nm).

Figure 1-33. Oil Pan

Figure 1-34. Filler Plug/Dipstick

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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 1-35. Obtain BELT TENSION GAUGE (HD-

35381).

NOTE Customers may purchase gauge from an authorized HarleyDavidson dealer.

0600a1x

3. See Figure 1-37. 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.

8844

1. Debris deﬂector

2. Belt deﬂection viewing window

3. Drive belt deﬂection graduations

4. Drive belt

Figure 1-36. Belt Deﬂection Window

d0164x1x

d0696x1x

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

Figure 1-35. Belt Tension Gauge (Part No. HD-35381)

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 1-37.).

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

10 lbs (4.5 kg) mark (5).

d. See Figure 1-36. 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 1-37. Checking Belt Deﬂection

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

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.

10 lbs (4.5 kg)

of force

NOTE

5/16-3/8 in.

(7.9-9.5 mm)

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1. Spring clip

2. Axle nut

3. Axle adjuster

7408

ADJUSTMENT

If belt adjustment is necessary, perform the following procedure:

1. See Figure 1-38. 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

Do not exceed 65 ft-lbs (88.1 Nm) when tightening the axle nut. Exceeding 65 ft-lbs (88.1 Nm) may cause the wheel bearings to seize during operation, which could result in death or serious injury.

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).

Figure 1-38. Axle Adjusters

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REAR BELT AND SPROCKETS 1.15

GENERAL

Inspect the drive belt and rear sprocket:

● At the 1000 mile (1600 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

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 1-39. 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.

1. Tooth

2. Groove

d0416x1x

Figure 1-39. Rear Sprocket

Rear Belt

See Figure 1-40. 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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d0598x1x

1 2

3 4

5 6

Stone

Cross-section shown

7 8

Figure 1-40. Drive Belt Wear Patterns

Table 1-4. Drive Belt Wear Analysis

PATTERN CONDITION REQUIRED ACTION

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

2External tooth cracks Replace belt

3Missing teeth Replace belt

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

5Fuzzy edge cord OK to run, but monitor condition

6 Hook wear Replace belt

7Stone damage Replace belt if damage is on the edge

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

Sprocket side of belt

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SUSPENSION ADJUSTMENTS 1.16

ALL MODELS BUT FXDX

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 1-41. 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.

FXDX MODELS

General

The FXDX motorcycle has a front suspension with cartridge valve 39 mm forks that adjust for compression and rebound damping and spring preload.

The rear suspension features shock absorbers that adjust for rebound damping as well as spring preload.

The front and rear suspension preload setting need to be adjusted for the rider’s weight. This setting should be made before the motorcycle is ridden any distance.

If the preload adjustment is correct, and the rebound and compression damping are set at the factory recommended points, the motorcycle should ride properly. If the rider is unhappy with these settings they can be changed. Evaluating and changing the rebound and compression damping is a very subjective process with many variables and should be approached carefully.

Damping is set at the factory for the average rider under normal riding conditions. The rider may wish to adjust these settings to compensate for individual riding styles, weight variations, or when carrying a passenger.

● Damping: Resistance to movement. Damping affects

how easily the suspension can move and limits oscillations of the system once movement has begun.

● Compression: Suspension is compressed when the

wheel moves up.

● Rebound: The suspension is rebounding when it is mov-

ing back from being compressed.

● Preload: The spring is compressed somewhat during

assembly. This initial compression provides a “loaded” condition in the spring. This initial compression is referred to as preload.

3587

Figure 1-41. Rear Shock Absorber Spring Adjustment

Preload Adjustment

11WARNING1WARNING

Be sure both shock absorber adjusting cams and front fork spring adjusting nuts are adjusted to same preload positions. Improper adjustments can adversely affect stability and handling, which could result in death or serious injury. (00037a)

NOTE Changes in load will require changes in the preload setting.

Carrying less weight than was used for setting up the suspension will require a reduction in the preload. Increasing the load will require an increase in the preload.

Front and rear suspension spring preload must be adjusted before any other adjustments can be attempted. This adjustment assures that the suspension has the proper amount of travel.

Spring preload is the most important suspension adjustment offered on your FXDX motorcycle. Correct setting of preload will result in a motorcycle that suits the rider’s size and weight.

You will need two people to carry out this adjustment.

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1. Mechanical preload adjusting cam

2. Rebound damping adjuster screw

d0422x1x

1. Mechanical preload adjusting nut

2. Preload lines

3. Rebound damping adjuster

4. Compression damping adjuster

d0423x1x

d0421a1x

Figure 1-42. Preload Adjustment

1. Take the motorcycle off the jiffy stand and bounce the rear up and down a few times to be sure the suspension is free and not binding.

2. See Figure 1-42. With the motorcycle unloaded, take the following measurements.

a. At the rear shock, measure the distance A, from the

upper shock bolt center to lower shock bolt center.

b. At the front fork, measure the distance B, from the

front axle center to the bottom of the lower triple clamp.

3. With the help of an assistant take the same measurements with the rider in full gear on the motorcycle. The assistant should help balance the motorcycle so the rider can keep both feet on the footpegs. Bounce a few times on the seat to be sure the suspension is free and not binding.

4. Subtract the second measurement from the ﬁrst. The difference, which is the squat, must be in the range of 0.5-

1.0 in. (12.7-25.4 mm). If it is not, adjustment is necessary.

5. See Figure 1-43. To adjust the rear shock spring preload, turn the mechanical preload adjusting cam (1) to the desired position using SPANNER WRENCH (Part No. HD-94700-52C). When returning to off-cam position, cams should be backed off in opposite direction.

6. See Figure 1-44. To adjust the front fork spring preload, turn the mechanical preload adjusting nut (1) with a 7/8 in. wrench. Observe lines (2) on cylindrical portion of adjusting nuts to keep adjustments equal on both forks.

a. Turning nut clockwise increases preload. b. Tu rning nut counterclockwise decreases preload.

The GVWR of the FXDX model is given in the Owner’s speciﬁcations. Under no circumstances is it to be exceeded.

NOTE

Figure 1-43. Rear Shock Adjustments

Figure 1-44. Front Fork Adjustments

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Rear Suspension Adjustments

REBOUND ADJUSTMENT

See Figure 1-45. Adjust rebound damping by using the screw on the top of the shock. Rotate toward “H” (Clockwise) to increases rebound damping. Rotate toward “S” (Counter clockwise) to decrease rebound damping.

There are 10 click stops between hard (position 1) and soft (position 10) settings for rebound damping adjuster screws.

If the preload adjustment is correct and you have the rebound damping set at the factory recommended points the motorcycle should handle and ride properly.

d0601x1x

7426

1. Adjuster

2. Lines

Figure 1-46. Front Fork Rebound Adjuster

7427

Figure 1-45. Rear Shock Rebound Adjuster

Front Suspension Adjustments

REBOUND ADJUSTMENT

See Figure 1-46. Located on top of each fork leg, the fork rebound adjuster knobs have 17 positions. Turning the adjuster knobs clockwise until they lock yields maximum rebound damping. Forks set in this position will have the slowest rebound. Adjusters turned fully counterclockwise will have the least amount of rebound damping. This adjustment will produce the fastest rebound. Make adjustments by counting the clicks while turning the adjuster knob(s).

COMPRESSION ADJUSTMENT

See Figure 1-47. The fork compression damping adjuster has 14 possible settings. Equal adjustments are made to the adjuster knobs at the base of each fork leg. Rotating the adjuster in the “H” direction (clockwise) gives a harder setting and rotating in the “S” direction (counterclockwise) yields softer damping.

Figure 1-47. Front Fork Compression Adjuster

Table 1-5. FXDX Factory

Suspension Settings

ADJUSTMENT

Front fork rebound Position 8

Front fork compression Position 3

Rear shock rebound Position 3

Rear shock preload Third cam step

See Figure 1-46. Factory setting for front fork preload has four lines visible and the ﬁfth line ﬂush with top of slider tube cap.

FROM FULL CLOCKWISE

(MAXIMUM HARD)

NOTE

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7428

STEERING HEAD BEARINGS 1.17

ADJUSTMENT

Check steering head:

● At the 1000 mile (1600 km) service interval. Adjust if nec-

essary.

● At every 10,000 mile (16,000 km) service interval there-

after. Adjust if necessary.

● At every 30,000 mile (48,280 km) service interval, disas-

semble, lube and inspect the steering head bearings. Adjust if necessary. See 2.21 STEERING HEAD.

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. See Figure 1-48. Loosen lower triple clamp pinch bolts.

6. 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.

7. The distance between the “fall-away” marks must be 1.0-

2.0 in. (25.4-50.8 mm). Tighten or loosen the fork adjuster nut/bolt until the measurement is within limits.

a. If the distance is more than 2.0 in. (50.8 mm),

loosen the adjuster nut. b. If it is less than 1.0 in. (25.4 mm), tighten the

adjuster nut.

NOTE On FXDWG models, the adjuster nut is tightened with a drift pin after loosening the top nut.

Figure 1-48. Lower Triple Clamp Pinch Bolt (Typical)

NOTE If adjustment seems to have no impact, check to see if fork tubes are stuck in clamps. If necessary, strike tubes with a dead blow hammer to free. Retest steering head bearing tension after freeing forks.

8. Tighten lower triple clamp pinch bolts.

a. FXDWG models: 30-35 ft-lbs (40.7-47.5 Nm). b. FXD, FXDL, FXDX models: 25-30 ft-lbs (33.9-40.7

Nm).

9. Repeat the “fall-away” procedure to be sure the adjust-

ment is correct.

LUBRICATION

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

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FRONT FORK OIL 1.18

REPLACING FORK OIL

Replace front fork oil:

● At every 20,000 mile (32,000 km) service interval.

● Prior to storage.

NOTE For FXDX models only, see 2.20 FRONT FORK: FXDX for fork oil replacement.

1. Support the motorcycle so the front end is off the ﬂoor

and the forks are fully extended.

2. See Figure 1-49. Remove the fork tube caps.

3. See Figure 1-50. Remove the drain screws from the bot-

tom of each fork and drain the fork oil.

4. Replace the drain screws and washers. Tighten screws

to 13-17 in-lbs (1.5-2.0 Nm).

5. Refer to Table 1-6. Fill the fork with Harley-Davidson

TYPE E FORK OIL (Part No. HD-99884-80).

6. Install both fork tube caps. Tighten caps to 11-22 ft-lbs

(14.9-29.8 Nm).

Table 1-6. Type E Fork Oil Amounts

MODEL OZ LITER IN. MM

7528

Figure 1-49. Fork Tube Cap

(Typical Except For FXDX)

7529

FXDWG 12.0 0.36 7.28 184.9

FXD/FXDL 10.6 0.31 6.69 169.9

NOTE Refer to Table 1-6. Fork oil amounts can be measured two ways.

● Use oz./cc measurement if fork is left in frame.

● Use in./mm measurement if fork is disassembled. In this

case, oil level is measured from top of fork tube, with spring removed and fork fully compressed.

Figure 1-50. Fork Drain Screw

(Typical Except For FXDX)

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SPARK PLUGS 1.19

INSPECTION

Check spark plugs:

● Inspect at every 5000 mile (8000 km) service interval.

● Replace every 10,000 mile (16,000 km) service interval.

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 1-51. 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 and/or enrichener usage 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.

5. Check electrode gap with a wire-type feeler gauge. Bend

6. Check condition of threads on cylinder head and plug. If

7. Apply LOCTITE ANTI-SEIZE to plugs. Install and tighten

8. Connect spark plug cables. Rear cylinder plug cable

Figure 1-51. Typical Spark Plug Deposits

the outside of the electrode so only a slight drag on the gauge is felt when passing it between electrodes. Proper gap measurement is 0.038-0.043 in. (0.97-1.09 mm).

necessary to remove deposits, apply penetrating oil and clean out with a thread chaser.

to 12-18 ft-lbs (16.3-24.4 Nm).

attaches to top coil terminal. Verify that cables are securely connected to coil and spark plugs.

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AIR CLEANER FILTER 1.20

REMOVAL

Inspect and service air cleaner ﬁlter:

● At every scheduled service interval.

1. See Figure 1-52. 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.

d0089x1x

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.

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

2. Air cleaner cover

3. T27 TORX screw (3) @ 30-50 in-lbs (3.4-5.6 Nm)

4. Bracket

5. Filter element

6. Gasket

7. Backplate

8. Breather hose (2)

Figure 1-52. Air Cleaner Assembly

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7429

Gasket

7430

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 1-53. Position new gasket on backplate.

2. See Figure 1-54. 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 1-52. 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).

Figure 1-53. Gasket Installation

Figure 1-54. 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:

● At the 1000 mile (1600 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

● If service is on muddy or dusty roads, clean and lubricate

components at shorter intervals.

CABLES AND HAND LEVERS

CAUTION

Do not lubricate the enrichener cable or inside of enrichener cable conduit. The cable must have sliding resistance to work properly.

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

FOOT SHIFT LEVER

Use WHEEL BEARING GREASE (Part No. 99855-89, can/ 99856-92, 14 oz. cartridge.

JIFFY STAND

Clean and lubricate the jiffy stand:

● At the 1000 mile (1600 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

If service is on muddy or dusty roads, clean and lubricate at shorter intervals. See 2.30 JIFFY STAND for more information.

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d0419x1x

1. Screws (2)

2. Throttle cable adjuster

3. Jam nuts (2)

4. Idle cable adjuster

d0418x1x

1. Throttle cable

2. Throttle cam

3. Idle cable

4. Spring

5. Cam stop

1 3

THROTTLE CABLES 1.22

CABLE INSPECTION, LUBRICATION AND ADJUSTMENT

Inspect the throttle and clutch cables:

● At the 1000 mile (1600 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

Inspection and Lubrication

1. See Figure 1-55. 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).

Figure 1-55. Throttle Cable Adjusters

Adjustment

1. See Figure 1-55. Tu rn the cable adjusters (2, 4) and jam

nuts (3) as short as they will go. Both cables should have zero adjustment at the start of this procedure.

2. Point the front wheel straight ahead.

a. Turn the throttle grip wide open and hold it there. b. Tu rn the throttle cable adjuster (2), lengthening the

sleeve, until the throttle cam just touches the cam stop. See Figure 1-56.

c. Tighten the adjuster jam nut and release the throttle.

3. Turn the front wheel full right.

4. Turn the idle cable adjuster, lengthening the sleeve until

the cable housing just touches the spring in the cable support sleeve.

11WARNING1WARNING

The throttle control must operate freely without binding. Irregular or sticking throttle response could cause a loss of control, leading to an accident which could result in death or serious injury.

5. Check adjustment.

a. Work the throttle grip to be sure the cable returns to

idle position when released.

b. If the cable does not return to idle, turn idle adjuster,

shortening the sleeve until correct adjustment is reached. Tighten the jam nut.

Figure 1-56. Idle Cable Connection

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ENRICHENER: CARBURETED 1.23

INSPECTION

CAUTION

Pay close attention to the vehicle’s warm-up time. Either excessive or insufﬁcient use of the enrichener may cause poor performance, erratic idle, poor fuel economy, spark plug fouling and equipment damage. (00164a)

Inspect enrichener operation:

● At every scheduled service interval.

CAUTION

Do not lubricate the enrichener cable or inside of enrichener cable conduit. The cable must have sliding resistance to work properly.

See Figure 1-57. Check fuel enrichener operation. The fuel enrichener knob (1) should open, remain open and then close without binding. The knurled plastic nut (2) next to the enrichener knob controls the ease or difﬁculty with which the cable slides within the cable conduit.

1. Loosen hex nut (5) at backside of mounting bracket.

2. Move cable assembly free of slot in mounting bracket.

3. Hold cable assembly at ﬂat (3) with an adjustable wrench. Turn knurled plastic nut (2) by hand to set sliding resistance.

a. Turn counterclockwise to reduce resistance until

knob slides inward unaided.

b. Tu rn clockwise to increase resistance until knob

remains fully out without holding and closes with relative ease.

4. Position cable assembly in slot in bracket. Tighten hex nut (5) at backside of bracket.

NOTE

The star washer (4) goes between the bracket and nut (5).

d0107x1x

1 2 3 4 5

1. Knob

2. Knurled plastic nut

3. Flat

4. Star washer

5. Hex nut

Figure 1-57. Enrichener Control

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d0381x1x

10022

IDLE SPEED/IGNITION TIMING: CARBURETED 1.24

IDLE SPEED INSPECTION

PART NO. SPECIALTY TOOL

HD-33413-A Carburetor idle adjuster

HD-33413-1A Idle adjuster tip

Check engine idle speed:

● At the 1000 mile (1600 km) service interval.

● At every 5000 mile (8000 km) interval thereafter.

NOTE

● The C.V. carburetor has an enrichener circuit that will

cause the engine to idle above the normal idle range (950-1050 RPM) with the engine at normal operating temperature and the enrichener knob pulled fully out.

● The increase in idle speed is intended to alert the rider

that the engine is warmed up to normal operating temperature and the enrichener knob should be pushed all the way in.

Figure 1-58. Idle Speed Adjustment Screw

CAUTION

Do not continue to use the enrichener when the engine is at full operating temperature. Doing so will result in fouled spark plugs.

● TECHNICIAN – Be sure the engine is warmed up to nor-

mal operating temperature and the enrichener knob is pushed all the way in BEFORE adjusting engine idle speed. Be aware that because there are variations in individual components, it is possible for a properly warmed up engine to idle above the normal idle range (950-1050 RPM) with the enrichener knob pulled PARTIALLY OUT.

1. On vehicles without tachometers, attach a DIGITAL MULTIMETER (Part No. HD-39978 or HD-39200) equipped with a RPM INDUCTIVE PICKUP (Part No. HD-41334) over front spark plug cable to monitor engine RPM.

2. Start motorcycle engine and let vehicle reach normal operating temperature with enrichener knob pushed fully in (enrichener closed).

3. See Figure 1-58. Set idle speed to 950-1050 RPM using the CARBURETOR IDLE ADJUSTER (Part No. HD33413-A) and TIP (Part No. HD-33413-1A).

a. Turn clockwise to increase idle speed. b. Tu rn counterclockwise to decrease idle speed.

IGNITION TIMING

Figure 1-59. Ignition Control Module Location

There is no ignition timing adjustment required. Should a sensor fail, the resulting trouble code will identify the problem. See CHECKING FOR TROUBLE CODES in DYNA MODELS ELECTRICAL DIAGNOSTIC MANUAL for more information.

See Figure 1-59. Ignition timing is controlled by the ignition control module based on input from:

● Manifold absolute pressure sensor.

● Crank position sensor.

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FUEL SUPPLY VALVE FILTER: CARBURETED 1.25

INSPECTION

PART NO. SPECIALTY TOOL

HD-23738-A Plastic Mity-Vac hand pump

HD-97087-65B Hose clamp pliers

Check fuel tank ﬁlter:

● At every 20,000 mile (32,000 km) service interval.

NOTE

See 4.6 FUEL SUPPLY VALVE: CARBURETED for more information.

1. See Figure 1-60. Turn ignition OFF. Turn fuel supply valve handle to OFF (horizontal) position.

11WARNING1WARNING

Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open ﬂame or sparks near gasoline. Gasoline is extremely ﬂammable and highly explosive, which could result in death or serious injury. (00002a)

2. See Figure 1-61. Remove the fuel hose (8) from the outlet nipple (6). Remove the vacuum hose from the vacuum nipple (4).

3. Attach a piece of fuel hose to fuel outlet nipple and route hose into a proper, clean gasoline container.

d0420a1x

Figure 1-60. Fuel Supply Valve OFF

1. Fuel tank ﬁlter

2. Fuel valve nut@ 15-20 ft-lbs (20.3-27.1 Nm)

3. Gasket

4. Vacuum nipple

5. Vent to atmosphere nipple

6. Fuel outlet nipple

7. Clamp

8. Fuel hose

9. Fuel valve adapter @ 22-26 ft-lbs (29.8-35.2 Nm)

OFF position

4. Turn valve handle to RESERVE (handle up).

5. Using the appropriate hose adapter, connect the PLASTIC MITY-VAC® HAND PUMP (Part No. HD-23738-A) to vacuum nipple (4) on valve. See Figure 1-62.

CAUTION

Do not apply a vacuum greater than 25 in. of Hg to the valve at the vacuum nipple to avoid damaging the valve diaphragm.

6. Gently apply a vacuum of 1-10 in. of Mercury (Hg) or just enough vacuum to get a good ﬂow of gasoline through the valve.

7. See Figure 1-61. After draining tank, turn the fuel valve nut (2) that attaches the valve to the fuel tank counterclockwise and remove the valve, gasket (3), and ﬁlter (1).

8. Clean or replace the fuel ﬁlter.

9. Coat valve threads with LOCTITE PIPE SEALANT WITH TEFLON.

10. Install new gasket on valve and install fuel ﬁlter.

1-48 2004 Dyna: Maintenance

s0540x4x

Figure 1-61. Fuel Supply Valve Assembly

HD-23738A

Figure 1-62. Mity-Vac Hand Pump, Part No. HD-23738-A

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HD-97087-65B

d0432x1x

11WARNING1WARNING

Do not thread fuel valve nut onto valve more than two turns to avoid “bottoming” nut on valve. This may cause a gasoline leak and a ﬁre hazard, which could result in death or serious injury.

NOTE If fuel valve adapter (9) is being replaced or reinstalled, coat threads with LOCTITE PIPE SEALANT WITH TEFLON. Tighten adapter to 22-26 ft-lbs (29.8-35.2 Nm).

11. Attach fuel supply valve to fuel valve adapter.

a. Thread fuel valve nut (2) on right hand threads of

fuel tank adapter two turns.

b. Hold fuel valve nut and thread body of fuel supply

valve into left hand threads of nut for two turns.

c. Hold valve and tighten fuel valve nut (clockwise) to

15-20 ft-lbs (20.3-27.1 Nm).

12. See Figure 1-63. Connect the fuel hose to the valve

using new clamp and HOSE CLAMP PLIERS (Part No. HD-97087-65B).

13. See Figure 1-64. Connect the fuel hose to the carburetor

using new clamp and HOSE CLAMP PLIERS (Part No. HD-97087-65B).

Figure 1-63. Hose Clamp Pliers, Part No. HD-97087-65B

CAUTION

Do not allow dirt or ﬂuids to get into the vacuum hose assembly that connects the fuel valve to the carburetor. Contaminants could block the vacuum signal or inhibit free motion of moving parts which could cause the fuel valve to remain open.

14. Connect vacuum line to vacuum nipple and ﬁll tank with

gasoline. Check for leaks at ﬁtting.

NOTE See Figure 1-61. If vacuum line is connected to the atmo- sphere vent nipple (5) (bottom nipple) the valve will not open.

15. Turn valve handle to ON and start engine. No special

procedures are required to start fuel ﬂow. Carefully inspect for leaks. Turn valve OFF and shut off engine after inspection is complete.

FUEL SYSTEM LINES AND FITTINGS

Inspect the fuel system lines:

● At every scheduled service interval.

● After the fuel tank ﬁlter has been serviced.

Check fuel system lines and ﬁttings for leaks.

Figure 1-64. Carburetor Fuel Hose Connection

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ENGINE MOUNTS 1.26

INSPECTION

Check engine mounts and stabilizer links:

● At every 10,000 mile (16,000 km) service interval.

1. See Figure 1-65. 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 1-65. Engine Mounts

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25 ft

(7.6 m)

d0110x1x

35 in. (0.9 m)

d0417x1x

HEADLAMP ALIGNMENT 1.27

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 1-66. 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 1-67. 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 1-66. Checking Headlamp Alignment

Figure 1-67. Headlamp Switch High Beam Setting

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ADJUSTMENT

All Models But FXDWG

1. See Figure 1-68. Remove snap plug on top of headlamp housing.

7431

Figure 1-68. Snap Plug (Typical)

2. See Figure 1-69. Loosen adjusting nut on top of headlamp.

7432

7433

1. Vertical adjusting bolt

2. Horizontal adjusting bolt

Figure 1-70. FXDWG Adjustments

FXDWG Model

1. See Figure 1-70. 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).

Figure 1-69. Adjusting Nut (Typical)

3. Tighten headlamp mounting nut to 120-180 in-lbs (13.6-

20.3 Nm), being careful not to move the headlamp in the process. Check alignment and reinstall snap plug.

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CRITICAL FASTENERS 1.28

INSPECTION

Inspect critical fasteners, except head bolts:

● At the 1000 mile (1600 km) service interval.

● At every 10,000 mile (16,000 km) service interval there-

after.

● Refer to Table 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, FXDWG 30-35 ft-lbs 40.7-47.5 Nm

Lower fork pinch bolts, all but FXDWG 25-30 ft-lbs 33.9-40.7 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 1.29

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 carburetor.

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. Adjust primary chain. See 1.10 PRIMARY CHAIN.

5. Inspect rear belt deﬂection. See 1.14 REAR BELT

DEFLECTION.

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

AND SPROCKETS.

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

TER.

8. Lubricate controls. See 1.21 CABLE AND CHASSIS

LUBRICATION.

9. Inspect operation of all electrical equipment and switches.

10. 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

Do not apply any oil to brake discs or brake pads. Oil on disc pads degrades braking efﬁciency and can result in an accident which could result in death or serious injury.

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

11WARNING1WARNING

2. Choose one of the following two methods for preparing your fuel system.

a. Fill fuel tank and add a gasoline stabilizer. Use one

of the commercially available gasoline stabilizers following the manufacturer’s instructions. Turn fuel supply valve off. Start motorcycle and run vehicle until fuel in carburetor ﬂoat bowl is gone and engine stops running.

b. Drain all gasoline from the fuel tank. Spray the

inside of the fuel tank with one of the commercially available rust preventatives. Follow 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)

● Unplug or turn OFF battery charger before discon-

necting 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)

● 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)

● Do not allow positive (+) battery cable to contact

ground with negative (-) cable connected. Resulting sparks can cause a battery explosion, which could result in death or serious injury. (00069a)

● 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)

● 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)

12. 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.

13. 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 1.30

GENERAL

11WARNING1WARNING

The troubleshooting section of this manual is intended solely as a guide to diagnosing problems. Carefully read the appropriate sections of this manual before performing any work. Observe all cautions and warnings. Failure to observe cautions and warnings 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 or fuel supply valve turned off.

2. Fouled spark plugs.

3. Engine ﬂooded with gasoline as a result of over use of enrichener.

4. Vacuum hose to automatic fuel supply valve disconnected, leaking, or pinched.

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

6. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

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

8. Loose wire connection at coil, battery, ECM connector or ignition control module connector.

9. Ignition timing incorrect due to faulty coil, ECM, ignition control module 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, ECM connector or ignition control module connector.

5. Carburetor controls not adjusted correctly.

6. Water or dirt in fuel system and carburetor.

7. Intake air leak.

8. Fuel tank vent hose and vapor valve plugged, or carburetor fuel line closed off, restricting fuel ﬂow.

9. Enrichener valve inoperative.

10. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

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

12. Faulty ignition coil.

13. 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, module, or sensor.

5. Battery nearly discharged.

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

7. Intermittent short circuit due to damaged wire insulation.

8. Water or dirt in fuel system, carburetor or ﬁlter.

9. Fuel tank vent system plugged or carburetor vent line closed off.

10. Carburetor controls misadjusted.

11. Air leak at intake manifold or air cleaner.

12. Damaged carburetor.

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13. Loose or dirty ECM connector or ignition control module connector.

14. Faulty Sensor(s): Manifold Absolute Pressure (MAP) and/or Crank Position (CKP).

15. Incorrect valve timing.

16. Weak or broken valve springs.

17. Damaged intake or exhaust valve.

A Spark Plug Fouls Repeatedly

1. Fuel mixture too rich or enrichener left on too long.

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.

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

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 tensioning spring or shoe worn.

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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Low Oil Pressure

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 or clean-out plug missing or leaking in cam support plate.

6. O-ring missing from cam support plate.

High Oil Pressure

1. Oil pan overﬁlled.

2. Bypass valve stuck in closed position.

ELECTRICAL SYSTEM

Alternator Does Not Charge

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.

Alternator Charge Rate Is Below Normal

1. Weak or damaged battery.

2. Loose connections.

3. Faulty regulator-rectiﬁer module.

4. Faulty stator and/or rotor.

Speedometer Operates Erratically

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

2. Loose connections.

TRANSMISSION

Shifts Hard

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 clutch dogs (inside transmission).

Jumps Out Of Gear

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.

Clutch Slips

1. Clutch controls improperly adjusted.

2. Insufﬁcient clutch spring tension.

3. Worn friction discs.

Clutch Drags Or Does Not Release

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.

Clutch Chatters

1. Friction discs or steel discs worn or warped.

CARBURETOR

Floods

1. Dirt or other foreign matter between valve and its seat.

2. Inlet valve sticking.

3. Inlet valve and/or valve seat worn or damaged.

4. Float misadjusted.

5. Leaky or damaged ﬂoat.

6. Excessive “pumping” of hand throttle grip.

7. See 4.2 FUEL SYSTEM TROUBLESHOOTING.

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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.

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NOTES

1-60 2004 Dyna: Maintenance

Page 67

CHASSIS 2

Table Of Contents

SUBJECT PAGE NO.

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

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

2.3 Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.4 Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.5 Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.6 Sealed Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.7 Wheel Lacing: 16 In. Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.8 Wheel Lacing: 19 In. Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.9 Wheel Lacing: 21 In. Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.10 Truing Laced Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2.11 Cast Wheel Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2.12 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2.13 Vehicle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2.14 Front Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2.15 Rear Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

2.16 Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

2.17 Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

2.18 Front Fork: FXD and FXDL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

2.19 Front Fork: FXDWG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

2.20 Front Fork: FXDX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

2.21 Steering Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

2.22 Rear Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

2.23 Rear Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

2.24 Belt Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

2.25 Debris Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

2.26 Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

2.27 Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

2.28 Front Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

2.29 Rear Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

2.30 Jiffy Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

2.31 Fork Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

2.32 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

2.33 Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

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SPECIFICATIONS 2.1

ITEM

Wheel base 62.5 1587.5 65.5 1663.7 63.2 1605.3 66.1 1678.9 Overall length 91.0 2311.4 94.0 2387.6 91.4 2321.6 93.6 2377.4 Overall width 36.8 934.7 35.4 899.2 36.8 934.7 35.0 889.0 Road clearance 5.4 137.2 4.6 116.8 5.9 149.7 5.4 137.2 Overall height 44.8 1137.9 44.8 1137.9 47.4 1204.0 47.8 1214.1 Saddle height 26.5 673.1 25.2 640.1 27.3 693.4 26.8 680.7

MODEL

FXDWG 12.0 0.36 5.2 19.7 1.1 4.2 FXDL

FXDX

See 2.20 FRONT FORK: FXDX for procedure to check and

ﬁll front forks on FXDX model motorcycles.

FXD FXDL FXDX FXDWG

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

FRONT FORK

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

10.6 0.31

FUEL TANK

TOTAL

4.9 18.5 0.9 3.4FXD

FUEL TANK

RESERVE

OIL TANK W/FILTER

3.0 2.8 24.0 0.71 26.0 0.77

TRANSMISSION

(APPROX.)

PRIMARY

CHAINCASE

ITEM

Dry weight 622 282 623 283 639 290 632 287 GVWR 1085 493 1085 493 1085 493 1085 493 GAWR front 390 177 390 177 390 177 390 177 GAWR rear 695 316 695 316 695 316 695 316

NOTE 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 FXDL FXDWG FXDX

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

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

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TORQUE VALUES 2.2

ITEM TORQUE NOTES

Belt sprocket screws 45-55 ft-lbs 61.0-74.6 Nm

Belt sprocket screws 55-65 ft-lbs 74.6-88.1 Nm

Brake disc screws, front 16-24 ft-lbs 21.7-32.5 Nm page 2-7

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

Brake hose bracket bolt 132

Debris deﬂector screws 40-60

Fork cap 22-29 ft-lbs 29.8-39.3 Nm FXDX & FXDXT, page 2-58

Fork damper screw 22-29 ft-lbs 29.8-39.3 Nm FXDX & FXDXT, page 2-58

Fork slider tube caps 11-22 ft-lbs 14.9-29.8 Nm FXD & FXDL, page 2-49

Fork slider tube caps 11-22 ft-lbs 14.9-29.8 Nm FXDWG, page 2-53

Fork stem bracket pinch bolt(s) 30-35 ft-lbs 40.7-47.5 Nm FXDX & FXDXT, page 2-59

Front axle nut 50-55 ft-lbs 67.8-74.6 Nm page 2-8

Front axle pinch bolt nut 25-30 ft-lbs 3.9-40.7 Nm FXD, FXDL, FXDX, FXDXT, page 2-8

Front axle slider cap nuts 60-132

Front brake caliper bleeder valve

Front brake caliper bridge bolts 28-38 ft-lbs 38.0-51.5 Nm page 2-40

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 2-73

Front master cylinder banjo bolt

Isolator mounting bolts 25 ft-lbs 33.9 Nm page 2-30

Jiffy stand bolt 19 ft-lbs 25.8 Nm page 2-77

Lower fork bracket pinch screws

Master cylinder clamp screw 70-80

Rear axle nut 60-65 ft-lbs 81.3-88.1 Nm page 2-11

Rear brake caliper bleeder valve

Rear brake caliper bridge bolts 28-38 ft-lbs 38.0-51.5 Nm page 2-45

Rear brake pad pins 15-16 ft-lbs 20.3-22.6 Nm 12 pt/0.25 in., page 2-41, page 2-46

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 2-41

28-38 ft-lbs 38.0-51.5 Nm Long bolt, 12 pt/10 mm, page 2-11, page 2-41

6-8

in-lbs

17-22 ft-lbs 23.0-29.8 Nm page 2-34

25-30 ft-lbs 33.9-40.7 Nm FXD, FXDL, FXDXT, page 2-49

in-lbs

80-100

in-lbs

14.9 Nm page 2-62

4.5-6.8 Nm page 2-11, Page 2-69

6.8-14.9 Nm FXDWG, page 2-8

9.0-11.3 Nm page 2-40

0.7-0.9 Nm page 2-42

7.9-9.0 Nm T27 TORX, page 2-33

9.0-11.3 Nm page 2-45

Laced wheels. Apply several drops of LOCTITE® thread locker 262 (red) to last few threads. page 2-11

Cast wheels. Apply several drops of LOCTITE® thread locker 262 (red) to last few threads. page 2-11

Apply several drops of LOCTITE® thread locker 243 (blue) to last few threads. page 2-10

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ITEM TORQUE NOTES

Rear brake reservoir cover screws

Rear fender sideplate nuts 12-18 ft-lbs 16.3-24.4 Nm

Rear fork pivot screw 45-50 ft-lbs 61.0-67.8 Nm page 2-67

Rear master cylinder banjo bolt

Rear master cylinder mounting nut

Rear shock fasteners 25-40 ft-lbs 33.9-54.2 Nm

Seat strap nut 60-90

Spoke nipples 40-50

Steering head pinch bolt 30-35 ft-lbs 40.7-47.5 Nm All but FXDWG, page 2-62

Throttle housing screws 35-45

Upper and lower shock mounts (FXD, FXDL, FXDWG)

Upper and lower shock mounts (FXDX)

Upper bracket pinch screws 21-27 ft-lbs 28.5-36.6 Nm FXDWG, page 2-62

Upper fork bracket pinch screws

Upper shock locknut (FXD, FXDL, FXDWG)

Upper shock locknut (FXDX) 60-80 ft-lbs 81.3-108.5 Nm page 2-65

Valve stem nut 12-15

6-8

in-lbs

17-22 ft-lbs 23.0-29.8 Nm page 2-37

40-50 ft-lbs 54.2-67.8 Nm page 2-37

in-lbs

25-40 ft-lbs 35-54 Nm

25-30 ft-lbs 33.9-40.7 Nm FXD, FXDL, FXDXT, page 2-49

60-80 ft-lbs 81.3-108.5 Nm page 2-64

in-lbs

0.7-0.9 Nm page 2-37, Page 2-46

FXD & FXDL, Apply several drops of LOCTITE® thread locker 243 (blue) to last few threads. page 2-76

FXDWG, Apply several drops of LOCTITE® thread locker 243 (blue) to last few threads. page 2-75

Apply several drops of LOCTITE® thread locker 243 (blue) to last few threads. page 2-11

6.78-10.17 Nm page 2-79

4.5-5.6 Nm 16 in., page 2-15

4.5-5.6 Nm 19 in., page 2-19

4.5-5.6 Nm 21 in., page 2-21

4.0-5.1 Nm page 2-70

Apply LOCTITE® thread locker 243 (blue) to last few threads. page 2-64

Apply LOCTITE® thread locker 243 (blue) to last few threads, page 2-65

1.4-1.7 Nm page 2-27

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VEHICLE IDENTIFICATION NUMBER 2.3

GENERAL

See Figure 2-1. The full 17 digit serial or Vehicle Identification Number (V.I.N.) is stamped on the right downtube socket of the steering head and on a label located on the right front downtube.

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

NOTE

See Figure 2-2. Always give the complete 17 digit V.I.N. when ordering parts or making inquiries about your motorcycle.

Market Designation

Model Designation

Engine Type

Varies - 1 thru 8

1 HD1 GE V 1*4 K 110000 *Varies - can be 0 thru 9 or X

Sample V.I.N. as it appears on the steering head - 1HD1GEV1*4Y110000 Sample abbreviated V.I.N. as it appears on the left crankcase - GEV4110000

1 - Manufactured for U.S.A. 5 - Manufactured for International

Model Year - 2004

7481

1. Stamping

2. Label

V - Twin Cam 88™ (Carbureted) W- Tw in Cam 88™ (EFI)

K-Manufactured in Kansas City, MO

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

GH -FXD GM -FXDI GJ -FXDX GR -FXDXI GD -FXDL GN -FXDLI GE -FXDWG GP -FXDWGI

Sequential Number

2-4 2004 Dyna: Chassis

Figure 2-2. Vehicle Identiﬁcation Number (V.I.N.)

Page 73

HOME

7497

1. Axle

2. Slider cap nuts and washers

1. Axle

2. Pinch bolt nut

7498

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.

NOTE

The FXDX has dual front brake calipers; both calipers must be removed before removing the front wheel. All other models have a single front brake caliper.

3. See Figure 2-3. Remove brake caliper(s). Support cali- per(s) 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. Remove wheel from forks. a. See Figure 2-4. For FXDWG models, loosen the

slider cap nuts (2) and pull the axle (1) free.

b. See Figure 2-5. For all other models, loosen pinch

bolt nut (2) and pull the axle (1) free from the wheel.

7482

Figure 2-4. Front Wheel Mounting: FXDWG

(Right Side)

Figure 2-5. Front Wheel Mounting: All But FXDWG

(Right Side)

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)

2004 Dyna: Chassis 2-5

Page 74

HOME

1. Axle

2. Right bearing spacer

3. Screw (10)

4. Right brake disc (FXDX only)

5. Hub plate (FXD only)

6. Bearing (2)

7. Sleeve

8. Cast wheel

9. Left brake disc

10. Left bearing spacer

11. Washer

12. Lockwasher

13. Axle nut

1. Axle

2. Right bearing spacer

3. Screw (5) (10 for FXDX)

4. Right brake disc (FXDX)

5. Bearing (2)

6. Sleeve

7. Wheel hub

8. Left 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. Weight

17. 21” Rim

18. 21” Laced wheel assembly

Figure 2-6. Cast Front Wheel

d0451x2x

2-6 2004 Dyna: Chassis

d0593x2x

Figure 2-7. Laced Front Wheel

Page 75

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11WARNING1WARNING

DISASSEMBLY

NOTE

See 2.12 TIRES to service tire or valve stem assembly.

Cast Wheel

1. See Figure 2-6. Remove spacers (2, 10) from left and right sides.

2. On wheels with dual brake discs, the left side of hub is marked for reference during assembly by two grooves cut in the hub face. If necessary, remove brake disc(s) (4, FXDX only, 9) and/or hub plate (5). Label all components so they may be installed in their original locations.

a. On left side of wheel, remove ﬁve screws (3) to

detach left brake disc (9).

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

remove right brake disc (4) or hub plate (5, FXD only).

Laced Wheel

1. See Figure 2-7. Remove spacers (2, 9) from left and right sides.

2. On wheels with dual brake discs, the left (primary disc) side of the hub is identiﬁed for reference during assembly by two grooves cut in the hub face. If necessary, remove brake disc(s) (4, 8). Label all components so they may be installed in their original locations.

a. On left side of wheel, remove ﬁve screws (3) to

detach left brake disc (8).

b. On FXDX models, remove ﬁve screws (3) to remove

right brake disc (4).

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

Do not allow brake ﬂuid, bearing grease, lubricants, etc. to contact brake rotor or reduced braking ability will occur which could result in death or serious injury.

1. See Figure 2-6. If necessary, install brake disc(s) (4, FXDX only, 9) and/or hub plate (5) in their original positions. Verify that brake disc(s) is clean. Tighten fasteners to 16-24 ft-lbs (21.7-32.5 Nm).

a. On left side of wheel, install ﬁve

attach left brake disc (9).

b. On right side of wheel, install ﬁve

attach right brake disc (4, FXDX only) or hub plate (5, FXD only).

2. Install spacers (2, 10) with largest chamfered end facing away from wheel.

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

WHEEL RUNOUT.

Laced Wheel

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

ING: 16 IN. RIM, 2.8 WHEEL LACING: 19 IN. RIM, or 2.9 WHEEL LACING: 21 IN. RIM.

Do not allow brake ﬂuid, bearing grease, lubricants, etc. to contact brake rotor or reduced braking ability will occur which could result in death or serious injury.

2. See Figure 2-7. If necessary, install brake disc(s) in their original positions. Verify that brake disc(s) is clean. Tighten fasteners to 16-24 ft-lbs (21.7-32.5 Nm).

a. On left side of wheel, install ﬁve

attach left brake disc (8).

b. On FXDX models, install ﬁve

attach right brake disc (4).

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) to

new

screws (3) to

new

screws (3) to

2004 Dyna: Chassis 2-7

Page 76

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INSTALLATION

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

2. See Figure 2-8. 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 pinch bolt nuts. Tighten axle nut to 50-55 ft-lbs (67.8-74.6 Nm). Hold axle stationary while tightening.

4. If servicing a vehicle with a single front brake caliper, advance to the next step. On models with dual front brakes, align calipers to brake discs. See Figure 2-9.

a. Loosen axle pinch bolt nuts.

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 (3) must the have edge of drill bit touching the edge of fork leg.

d. Tighten the axle pinch bolt nuts to 25-30 ft-lbs (33.9-

40.7 Nm).

e. Withdraw drill bit and advance to step 6.

5. Tighten axle hardware on single caliper vehicles.

a. See Figure 2-5. On FXD models, tighten the axle

pinch bolt nut to 25-30 ft-lbs (33.9-40.7 Nm).

b. See Figure 2-4. On FXDWG models, tighten the

slider cap nuts to 60-132

6. 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 (38.51.5 Nm).

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

(38.51.5 Nm).

in-lbs

(6.8-14.9 Nm).

7484

1. Spacer (2)

2. Axle nut, lockwasher and washer

Figure 2-8. Front Axle Assembly

7472

1. Axle

2. Drill bit

3. Contact point

Figure 2-9. Dual Brake Disc Alignment

11WARNING1WARNING

Whenever a wheel is installed, BEFORE moving motorcycle, you must pump brake ﬂuid until the pistons push the pads against the brake disc. If you don’t pump ﬂuid pressure up again, the brakes will not be available to stop the motorcycle which could result in death or serious injury.

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

2-8 2004 Dyna: Chassis

Page 77

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1. Spring clip

2. Axle nut

3. Washer

7408

1. Upper mounting nuts

2. Lower mounting nuts and washers

3. Belt guard

7485

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 2.25 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 spring clip (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

shock absorber nuts (1).

6. Remove left and right washers (2).

7. Disconnect shock absorbers from lower shock mounting bolts. Allow rear fork and wheel to lower.

8. Remove belt guard (3). See 2.24 BELT GUARD.

9. Remove axle from wheel.

10. Move wheel forward and slip belt off sprocket.

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

11. 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 absorber nuts and

NOTE

Figure 2-10. Rear Axle

DISASSEMBLY

NOTE With the exception of the sprocket screw washer (16), component parts for cast and laced rear wheels are identical.

1. See Figure 2-12. Remove spacers (2, 10) 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).

Figure 2-11. Rear Shock Mount

2004 Dyna: Chassis 2-9

Page 78

HOME

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. Cover (HDI only)

14. Spring clip

15. Screw (5)

16. Washer (5)

CLEANING AND INSPECTION

d0452x2x

Figure 2-12. Rear Wheel/Hub

ASSEMBLY

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.

2-10 2004 Dyna: Chassis

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

ING: 16 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).

Page 79

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11WARNING1WARNING

3. 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. On cast wheels, tighten screws to 55-65 ft-lbs (74.6-

88.1 Nm).

c. On laced wheels, tighten screws to 45-55 ft-lbs

(61.0-74.6 Nm).

4. Install spacers (2, 10) into hub with largest chamfered end facing away from wheel.

5. 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.

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.

4. See Figure 2-11. Attach rear shocks. a. Apply two or three drops of LOCTITE THREAD-

LOCKER 243 (blue) to threads of upper and lower shock mounting bolts.

b. Lift rear fork and install both shock absorbers with

washers and mounting nuts (1, 2).

c. Tighten all fasteners to 25-40 ft-lbs (33.9-54.2 Nm).

11WARNING1WARNING

Do not exceed 65 ft-lbs (88.1 Nm) when tightening the axle nut. Exceeding 65 ft-lbs (88.1 Nm) may cause the wheel bearings to seize during vehicle operation, which could result in death or serious injury.

5. 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. Check to see if the spring clip (2) can be installed. If

required, tighten axle nut to no more than 65 ft-lbs (88.1 Nm) and align axle hole and nut slots. Install spring clip.

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

in-lbs

(4.5-6.8 Nm). See 2.25 DEBRIS DEFLECTOR.

7. Install belt guard. See 2.24 BELT GUARD.

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

9. Verify correct axle alignment (2.13 VEHICLE ALIGN-

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

2004 Dyna: Chassis 2-11

Page 80

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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.

d0606x2x

d0559x2x

1. Forcing screw

2. Nut

3. Washer

4. Nice bearing

5. Bridge

6. Collet with ball bearing inside

Figure 2-14. Removal Tool

Figure 2-13. Wheel Bearing Inspection

(Front Wheel Shown)

REMOVAL

PART NO. SPECIALTY TOOL

HD-44060 Wheel bearing installer/remover

1. Remove wheel from motorcycle. See 2.4 FRONT

WHEEL or 2.5 REAR WHEEL as appropriate. On vehi-

cles with a single front brake caliper, 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).

d0560x2x

1. Forcing screw

2. Nut

Figure 2-15. Remove Bearing

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.

2-12 2004 Dyna: Chassis

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d0561x2x

d0562x2x

1. Threaded rod

2. Nut

3. Washer

4. Nice bearing

5. Pilot

6. Wheel bearing

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.

SPECIALTY TOOL

NOTE

new

bearing (6) on rod

Figure 2-16. Installation Tool Support Plate

4. Reverse tool and install opposite side bearing.

5. On cast front wheels for single caliper vehicles, install hub plate opposite front brake disc.

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)

Figure 2-17. Installing Bearing

NO. DESCRIPTION PA RT NO.

1Bridge HD-44060-5 2Steel ball 12547 3Forcing screw HD-44060-4

4 Nut 10210 5Washer 12004 6 Nice bearing RS25100-200 7Lubricant 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

2004 Dyna: Chassis 2-13

Page 82

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WHEEL LACING: 16 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.

Torx head spokes, the 16 in. laced wheel hub and the 16 in. wheel are shown below.

d0459x2x

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.

d0457x2x

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

d0458x2x

lower

row spoke, place the ﬁrst spoke into the

Figure 2-21.

Figure 2-19.

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.

2-14 2004 Dyna: Chassis

Narrow flange

lower

row

Figure 2-22.

5. Place the ﬁrst 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

upper

row spoke into the hub as shown

Figure 2-23.

Page 83

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d0465x2x

d0466x2x

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

d0462x2x

9. Insert any

upper

row spoke into hub and angle spoke

counterclockwise. Place spoke into appropriate rim hole.

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.

d0463x2x

Figure 2-25.

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

Figure 2-27.

10. Install remaining nine upper row spokes.

Figure 2-28.

11. Tighten spoke nipples to 40-50

in-lbs

(4.5-5.6 Nm).

12. True wheel. See 2.10 TRUING LACED WHEEL.

d0464x2x

Figure 2-26.

2004 Dyna: Chassis 2-15

Page 84

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WHEEL LACING: 19 IN. RIM 2.8

PROCEDURE

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.

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.

7. Swing all bottom ﬂange outer spokes (short head) clock-

wise.

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 overlap-

ping 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.

●

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.

d0660x2x

1. Outer spoke (short head)

2. Inner spoke (long head)

Figure 2-29. Lacing 19-in. Wheel Hub

d0661x2x

Figure 2-30. Bundling Top Spokes

d0662x2x

Figure 2-31. Valve Stem Hole Location

2-16 2004 Dyna: Chassis

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d0674x2x

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.

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. Ve rify 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).

d0664x2x

Figure 2-33. Completed Spokes: Bottom Flange Outer

d0665x2x

d0663x2x

Figure 2-34. Beginning Spoke: Bottom Flange Inner

Figure 2-32. Beginning Spoke: Bottom Flange Outer

Figure 2-35. Completed Spokes: Bottom Flange Inner

2004 Dyna: Chassis 2-17

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15. See Figure 2-36. Undo each top bundle and fan the spokes out (in a starburst pattern) around the top rim edge.

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. Ve rify 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

d0667x2x

Figure 2-38. Beginning Spoke: Top Flange Inner

d0670x2x

Figure 2-36. Fanning Top Flange Spokes

2-18 2004 Dyna: Chassis

Figure 2-39. Completed Spokes: Top Flange Inner

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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 40-50

in-lbs

(4.5-5.6 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

2004 Dyna: Chassis 2-19

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WHEEL LACING: 21 IN. RIM 2.9

GENERAL

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.

PROCEDURE

1. See Figure 2-42. 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.

d0467x2x

d0468x2x

Figure 2-43.

d0469x2x

Figure 2-42.

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

3. See Figure 2-43. Using any ﬁrst spoke into the rim hole, angled to correctly accept the spoke, on the upper half of the rim centerline.

4. See Figure 2-44. Install the rest of lower row spokes in every fourth hole.

5. See Figure 2-45. Place the ﬁrst 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.

2-20 2004 Dyna: Chassis

lower

row spoke, place the

upper

row spoke into the

Figure 2-44.

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Figure 2-45.

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6. See Figure 2-46. Install the remaining nine upper row spokes into every fourth remaining hole above the rim centerline. This completes spoke installation on this side.

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8. See Figure 2-48. Place the remaining nine lower row spokes, angled clockwise, into hub and rim.

Figure 2-46.

7. See Figure 2-47. 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.

d0472x2x

Figure 2-47.

Figure 2-48.

9. See Figure 2-49. Insert any

upper

row spoke into hub and angle spoke counterclockwise into appropriate rim hole. Install remaining upper row spokes.

Figure 2-49.

10. Tighten spoke nipples to 40-50

in-lbs

(4.5-5.6 Nm).

11. True wheel. See 2.10 TRUING LACED WHEEL.

2004 Dyna: Chassis 2-21

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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 ings were installed, wheels may be trued with only the bearings and center spacer installed.

new

bear-

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 8-50. 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 2-52.

7473

Figure 8-50. Front Wheel Hub Offset Dimension

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NOTES

The

FRONT WHEEL

as listed in Table 2-1.

offset dimension, distance “A”, must be

Table 2-1. Offset Dimensions

WHEEL RIM SIZE IN. MM.

Front 21 1.640-1.660 41.656-42.164

19 0.837-0.857 21.260-21.768

Rear 16 1.472-1.492 37.389-37.897

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.

NOTE

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.

Figure 2-51. Rear Wheel Hub Offset Dimension

2-22 2004 Dyna: Chassis

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Offset:

1.472-1.492 in.

Hub on 16 in. rear spoke - all models

Offset: 0.837-0.857 in.

Hub (brake disc side) on 19 in. front spoke all but FXDWG

Figure 2-52. Laced Hub Offset Dimension

Offset: 1.640-1.660 in.

Hub on 21 in. front spoke FXDWG

2004 Dyna: Chassis 2-23

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RADIAL TRUING

1. See Figure 2-53. 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 40-50 in-lbs (4.5-5.6 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.

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Figure 2-53. Truing Rim Radially

2-24 2004 Dyna: Chassis

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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 2-54. 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 2-55. Check for radial runout as shown. Replace the wheel if runout exceeds 0.030 in. (0.76 mm).

Figure 2-55. Checking Radial Runout

Figure 2-54. Checking Lateral Runout

2004 Dyna: Chassis 2-25

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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 your 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).

Tu beless 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

● Never repair a tire with less than 1/16 in. (1.6 mm)

tread depth. Inadequate tread depth can cause an accident which could result in death or serious injury.

● 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)

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Figure 2-56. Starting Tire Off Rim

CAUTION

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.

NOTE It is not always necessary to completely remove tire from rim. Removing one side allows the tire to be inspected.

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

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 2-56. 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.

NOTE

It is not necessary to use tools to remove tubeless tires. Make sure beads are well lubricated before removing from rim.

2-26 2004 Dyna: Chassis

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.

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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 (stock) tire valves and

valve caps. A valve or valve and cap combination that is too long may interfere with (strike) adjacent components, damage the valve and cause rapid tire deﬂation. Rapid tire deﬂation could cause loss of control and could result in death or serious injury.

● Aftermarket valve caps that are heavier than the stock

cap may have clearance at slow speeds; but, at high speed the valve/cap will be moved outward by centrifugal force. This outward movement could cause the valve/cap to strike the adjacent components, damage the valve and cause rapid tire deﬂation. Rapid tire deﬂation could cause loss of control and could result in death or serious injury.

● Damaged or leaking valves must be replaced.

1. See Figure 2-57. 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).

11WARNING1WARNING

Do not inﬂate more than 40 psi (276 kPa) to seat the beads. Inﬂating the tire more than 40 psi (276 kPa) to seat the beads can cause the tire rim assembly to burst with force sufﬁcient to cause death or serious injury. If the beads fail to seat at 40 psi (276 kPa), deﬂate and relubricate the bead and rim and reinﬂate to seat the beads but do not exceed 40 psi (276 kPa).

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.

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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 2-58. 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 2-59. 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 2-57. Valve Stem

Figure 2-58. Starting Bead on Rim

Figure 2-59. Starting Second Bead on Rim

2004 Dyna: Chassis 2-27

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CHECKING TIRE RUNOUT

Radial Runout

1. See Figure 2-60. 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 2-61. 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.

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Figure 2-60. Radial Tire Runout

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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 Table

2-2.

Table 2-2. 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. 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.

2-28 2004 Dyna: Chassis

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7477

VEHICLE ALIGNMENT 2.13

INSPECTION

11WARNING1WARNING

Vehicle alignment is very important to assure proper handling and vibration control. Improper alignment could lead to an accident which could result in death or serious injury.

NOTE

Check the stabilizer for wear every 10,000 miles (16,000 km).

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 2-63. 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 2-62. 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.

5. See Figure 2-64. 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

Figure 2-62. Measuring Alignment

spins freely. Do this by placing a center stand or blocking under the frame.

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Grommet

1.25 in.

(32 mm)

10.0 in.

(254 mm)

Figure 2-63. Alignment Tool

2004 Dyna: Chassis 2-29

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7. See Figure 2-65. 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.

CAUTION

d0481x2x

Chassis

Powertrain

Correct by adjusting belt adjusters

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.

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.

11WARNING1WARNING

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. If there is not this minimum clearance, it is possible for the bolt head to damage the fuel tank, which could result in death or serious injury.

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).

Rear fork

hole

Rear axle

center

Distance ‘A’ must be equal

Figure 2-64. Rear Wheel Misaligned

7478

1. Top stabilizer link

2. Bolt

3. Jam nut

4. Adjusting stud (nut)

Figure 2-65. Top Stabilizer

2-30 2004 Dyna: Chassis

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1. Dual disc master cylinder

2. Bore stamp size

3. Single disc master cylinder

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1. Groove

2. 5/32 in. (4mm) thick cardboard insert

FRONT BRAKE MASTER CYLINDER 2.14

GENERAL

11WARNING1WARNING

Do not use an 11/16 in. bore master cylinder assembly on single disc (one caliper) models. These master cylinder assemblies are not interchangeable. Using the wrong assembly can adversely affect braking efﬁciency or result in brake failure which could result in death or serious injury.

See Figure 2-66. Master cylinders designed for dual disc (two caliper) operation have an 11/16 inch (17.5 mm) bore, while those that are 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.

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 the master cylinder assembly without ﬁrst placing a 5/32 inch (4 mm) thick cardboard insert between the brake lever and lever bracket. Removal without the insert may result in damage to the rubber boot and plunger of the front stoplight switch.

3. See Figure 2-67. 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

Always wear proper eye protection when removing retaining rings. Slippage may propel the ring with enough force to cause an accident. This could result in death or serious injury.

5. Remove retaining ring (18) from pivot pin groove at bottom of master cylinder bracket.

Figure 2-66. Bore Sizes

Figure 2-67. Cardboard Insert

2004 Dyna: Chassis 2-31

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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

Shoulder

Flat side

O-ring groove

Service parts kit contains items 1-7.

● 9/16 in. bore - Part No. 45006-96C

● 11/16 in. bore - Part No. 45072-96C

Figure 2-68. Front Brake Master Cylinder

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).

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CAUTION

To prevent dirt and other contaminants from entering the master cylinder reservoir, thoroughly clean the cover before removal.

11. Remove both screws (13), cover (11) and the cover gasket (10).

2-32 2004 Dyna: Chassis