How it Works
Maintenance
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Dyna
User Manual
74 pgs2.2 Mb0
Table of contents
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Maintenance Dyna User Manual

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Page 1
able Of Contents
T
SUBJECT PAGE NO.
1.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Side Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
NOTE
This section provides information unique to the FXDP police model motorcycle. Any infor­mation not presented in this supplement can be found in the Dyna Models Service Man­ual.
MAINTENANCE 1
Page 2
Page 3
HOME

MAINTENANCE SCHEDULE 1.1

Table 1-1. Maintenance Schedule
1
1
1
1
2
2
2
2
3
3
3
3
4
4
4
4
5
7
0
5
0
0
0
0
0
M
M
I
I
I
7
8
6
0
0
0
0
0
0
0
K
K
M
M
MAINTENANCE TASK
AND SERVICE DATA
Engine oil (*)
Oil level:
Dipstick level depends on vehicle temperature
Engine oil filter (*)
Filter tightening:
Hand tighten oil filter 1/2 to 3/4 turn after gasket surface contacts filter mounting surface.
1
2
5
7
0
2
5
7
0
2
5
7
0
2
5
7
0
5
0
5
0
5
0
5
0
5
0
5
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
M
M
M
M
M
M
M
M
I
I
I
I
I
I
P R
1 E R
D E
4
6
0
0
0
I
0
0
K
K
M
M
IR
RRRRRRRRRRRRRRRRRRRR
R
RRRRRRRRRRRRRRRRRRRR
1
1
8
2
0
0
0
0
0
0
K
K
M
M
2
6
0
0
0
0
0
0
0
K
K
M
K
M
M
M
I
I
2
2 4 0 0 0
3
8
2
0
0
0
0
0
0
K
K
M
M
0
M
M
I
I
3
4
6
0
0
0
0
0
0
0
K
K
M
M
0
0
0
M
M
I
I
4
4
4
8
0
0
0
0
0
0
K
K
M
M
0
0
0
0
0
M
M
I
I
5
5
2
6
0
0
0
0
0
0
K
K
M
M
0
5
0
0
0
0
0
M
M
I
I
I
6
6
0
4
0
0
0
0
0
0
K
K
M
M
2
5
5
0
0
0
0
0
M
M
I
6
7
8
2
0
0
0
0
0
0
K
K
M
M
Battery (*)
Brake fluid level and condition
Brake fluid type:
D.O.T. 5 SILICONE BRAKE FLUID Part No. 99902-77 (12 oz.) or 99901-77 (gallon)
Brake pads and discs for wear
Minimum pad thickness:
0.04 in. (1.02 mm)
II
Maximum brake disc lateral runout:
0.008 in. (0.2 mm)
Tire pressure and inspect tires for wear/damage (*)
II
Primary chain adjustment
Deflection:
Cold: 5/8-7/8 in. (15.9-22.2 mm) Hot: 3/8-5/8 in. (9.5-15.9 mm)
Tab le Code:
A
- Adjust.
I
- Inspect, and if necessary, correct, adjust, clean or replace.
L
- Lubricate with specified lubricant.
R
- Replace or change.
I
IIIIIIIIIIIIIIIIIIII
I
I
I I I I I I I I I I
IIIIIIIIIIIIIIIIIIII
IIIIIIIIIIIIIIIIIIII
I I I I I I I I I I
T
- Tighten to proper torque.
X
-Perform.
D
- Disassemble, lubricate and inspect.
(*)- Also perform prior to storage or annually.
2003 Dyna Police: Maintenance 1-1
Page 4
HOME
MAINTENANCE TASK
AND SERVICE DATA
Primary chain lubricant
Lubricant level:
Visible between clutch and chain­case inner wall with vehicle upright, 26 oz (768.8 ml).
Lubricant type:
Part No. 99887-84 (quart) or 99886-84 (gallon)
Table 1-1. Maintenance Schedule
1
1
1
1
2
2
1
2
5
7
0
2
5
7
0
5
0
5
0
0
0
0
0
0
M
M
I
P R
1
4
E
6
0
R
0
0
I
0
0
D
K
K
E
M
M
R
RRRRRRRRRRRRRRRRRRRR
0
0
0
M
M
I
I
1
8
2
0
0
0
0
0
0
K
K
M
M
5
0
0
0
0
M
M
I
M
I
I
1
2
6
0
0
0
0
0
0
0
K
K
K
M
M
M
0
0
5
0
0
0
0
0
0
0
M
M
I
I
2
2
3
4
8
2
0
0
0
0
0
0
0
0
0
K
K
M
M
2
2
5
5
0
0
0
0
0
M
M
I
I
I
3
4
6
0
0
0
0
0
0
0
K
K
M
M
2
3
3
3
3
4
4
4
4
7
0
2
5
7
0
2
5
0
5
0
5
0
0
0
M
4 4 0 0
0 K M
0
0
0
M
M
I
K M
M
I
I
4
5
8
2
0
0
0
0
0
0
K
K
M
M
0
0
0
0
0
0
0
M
M
I
I
5
6
6
6
0
4
0
0
0
0
0
0
0
0
0
K
K
M
M
5
5
0
0
0
0
0
M
M
I
I
6
7
8
2
0
0
0
0
0
0
K
K
M
M
5
7
0
5
0
0
0
0
0
M
M
I
I
I
7
8
6
0
0
0
0
0
0
0
K
K
M
M
Clutch adjustment
Hand lever free play:
1/16-1/8 in. (1.6-3.2 mm)
Transmission lubricant (*)
Lubricant level:
Bottom edge of FULL mark on dip­stick with vehicle upright.
Lubricant type:
Part No. 99892-84 (quart)
Drain plug:
14-21 ft-lbs (19.0-28.5 Nm)
Rear belt deflection inspection (*)
Deflection:
5/16-3/8 in. (7.9-9.5 mm) Bottom strand with 10 lb. (4.5kg) upward force.
Specialty tool:
Part No. HD-35381
Rear belt and sprocket (*)
Steering head bearing
Front fork oil
X
R
II
I
A
X X X X X X X X X X
IRIRIRIRIRIRIRIRIRIR
IIIIIIIIIIIIIIIIIIII
I I I I I I I I I I
A A D A A
R
R
Tab le Code:
A
- Adjust.
I
- Inspect, and if necessary, correct, adjust, clean or replace.
L
- Lubricate with specified lubricant.
R
- Replace or change.
1-2 2003 Dyna Police: Maintenance
T
- Tighten to proper torque.
X
-Perform.
D
- Disassemble, lubricate and inspect.
(*)- Also perform prior to storage or annually.
Page 5
HOME
MAINTENANCE TASK
AND SERVICE DATA
Table 1-1. Maintenance Schedule
1
1
1
1
2
2
1
2
5
7
0
2
5
7
0
5
0
5
0
5
0
0
0
0
0
0
M
P R
1
E
6
R
0
I
0
D
K
E
M
0
M
M
I
I
4
8
0
0
0
0
0
0
K
K
M
M
0
0
0
M
M
I
I
1
1
2
6
0
0
0
0
0
0
K
K
M
M
0
0
0
0
0
M
M
I
I
2
2
0
4
0
0
0
0
0
0
K
K
M
M
0
5
0
0
0
0
0
M
M
I
I
2
3
8
2
0
0
0
0
0
0
K
K
M
M
2
2
5
5
0
0
0
0
0
M
M
I
I
I
3
4
6
0
0
0
0
0
0
0
K
K
M
M
2
3
3
3
3
4
4
4
4
7
0
2
5
7
0
2
5
0
5
0
5
0
0
0
0
0
M
M
I
4
4
4
8
0
0
0
0
0
0
K
K
M
M
0
0
0
M
M
I
I
5
5
2
6
0
0
0
0
0
0
K
K
M
M
0
0
0
0
0
M
M
I
I
6
6
0
4
0
0
0
0
0
0
K
K
M
M
5
5
0
0
0
0
0
M
M
I
I
6
7
8
2
0
0
0
0
0
0
K
K
M
M
5
7
0
5
0
0
0
0
0
M
M
I
I
I
7
8
6
0
0
0
0
0
0
0
K
K
M
M
Check air suspension - pressure, operation and leakage
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)
Air cleaner filter (*)
Cover screw torque:
36-60
in-lbs
(4.1-6.8 Nm)
Lubricate controls (*)
Front brake hand lever, clutch hand lever, throttle control cables, clutch control cable, rear brake pedal and jiffy stand
Shift Lever
Operation of throttle controls
Enrichener operation
I
I
I
L
L
I
I
I I I I I I I I I I
I R I R I R I R I R
IIIIIIIIIIIIIIIIIIII
L L L L L L L L L L
L L L L L L L L L L
IIIIIIIIIIIIIIIIIIII
IIIIIIIIIIIIIIIIIIII
Engine idle speed
Idle speed:
950-1050 RPM
Fuel supply valve filter screen
Filter hex fitting torque:
15-20 ft-lbs (20.3-27.1 Nm)
Fuel system lines and fittings (*)
Repack rear fork bearings
Hinges, latches - saddlebags, fuel door
Tab le Code:
A
- Adjust.
I
- Inspect, and if necessary, correct, adjust, clean or replace.
L
- Lubricate with specified lubricant.
R
- Replace or change.
I
I
L
I I I I I I I I I I
X
IIIIIIIIIIIIIIIIIIII
X
L L L L L L L L L L
T
- Tighten to proper torque.
X
-Perform.
D
- Disassemble, lubricate and inspect.
(*)- Also perform prior to storage or annually.
X
X
2003 Dyna Police: Maintenance 1-3
Page 6
HOME
MAINTENANCE TASK
AND SERVICE DATA
Check oil and brake lines for leaks
Table 1-1. Maintenance Schedule
1
1
1
1
2
2
1
2
5
7
0
2
5
7
0
5
0
5
0
0
0
0
0
0
M
M
I
P R
1
4
E
6
0
R
0
0
I
0
0
D
K
K
E
M
M
I
0
0
0
M
M
I
I
1
8
2
0
0
0
0
0
0
K
K
M
M
IIIIIIIIIIIIIIIIIIII
5
0
0
0
0
M
M
I
M
I
I
1
2
6
0
0
0
0
0
0
0
K
K
K
M
M
M
0
0
5
0
0
0
0
0
0
0
M
M
I
I
2
2
3
4
8
2
0
0
0
0
0
0
0
0
0
K
K
M
M
2
2
5
5
0
0
0
0
0
M
M
I
I
I
3
4
6
0
0
0
0
0
0
0
K
K
M
M
2
3
3
3
3
4
4
4
4
7
0
2
5
7
0
2
5
0
5
0
5
0
0
0 M
4
4
0
0
0 K M
0
0
0
M
M
I
K M
M
I
I
4
5
8
2
0
0
0
0
0
0
K
K
M
M
0
0
0
0
0
0
0
M
M
I
I
5
6
6
6
0
4
0
0
0
0
0
0
0
0
0
K
K
M
M
5
5
0
0
0
0
0
M
M
I
I
6
7
8
2
0
0
0
0
0
0
K
K
M
M
5
7
0
5
0
0
0
0
0
M
M
I
I
I
7
8
6
0
0
0
0
0
0
0
K
K
M
M
Engine mounts
Operation of all electrical equip­ment and switches (*)
All critical fasteners except engine head bolts
Road test
Tab le Code:
A
- Adjust.
I
- Inspect, and if necessary, correct, adjust, clean or replace.
L
- Lubricate with specified lubricant.
R
- Replace or change.
I
I
IIIIIIIIIIIIIIIIIIII
T
X
XXXXXXXXXXXXXXXXXXXX
T T T T T
I I I I
T
- Tighten to proper torque.
X
-Perform.
D
- Disassemble, lubricate and inspect.
(*)- Also perform prior to storage or annually.
1-4 2003 Dyna Police: Maintenance
Page 7
HOME
9845
1. Rear turn signal lamp
2. Tail/stop lamp
3. Battery
4. Air cleaner
5. Fuel filler cap
6. Throttle control grip
7. Front brake hand lever
8. Front brake master cylinder/reservoir
9. Front turn signal/running lamp
10. Fork Lock
11. Rear brake pedal
12. Footrest
13. Engine oil fill plug/dipstick
14. Engine oil pan drain
15. Transmission fill plug
16. Transmission drain plug
17. Rear brake master cylinder/reservoir
18. Electric starter motor
10
11121314
15161718
7
9
6
5
4
3
2
1
8

SIDE VIEWS 1.2

9844
3
2
1
1. Pursuit lamp
2. Headlamp
3. Speedometer/tachometer
4. Front turn signal/running lamp
5. Clutch hand lever
6. Fuel gauge
7. Ignition/light key switch
8. Horn
17
76
16
4
21
9. Enrichener
10. Fuel supply valve
11. Ignition coil
12. Accessory connector
13. Main 30 amp circuit breaker,
5
20
(under seat)
system fuses/relays (under electrical panel cover)
19
18
8
15
14
9
10
11
12
13
14. Primary drain plug
15. Clutch inspection cover
16. Primary chain inspection cover
17. Jiffy stand
18. Footrest
19. Engine oil filter
20. Voltage regulator
21. Gear shifter lever
Figure 1-1. FXDP (Left Side View)
Figure 1-2. FXDP (Right Side View)
2003 Dyna Police: Maintenance 1-5
Page 8
HOME
NOTES
1-6 2003 Dyna Police: Maintenance
Page 9
T
able Of Contents
CHASSIS 2
SUBJECT PAGE NO.
2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 Saddlebags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6 Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.7 Pursuit Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.8 Footboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.9 Radio Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
NOTE
This section provides information unique to the FXDP police model motorcycle. Any infor­mation not presented in this supplement can be found in the Dyna Models Service Man­ual.
Page 10
Page 11
HOME

SPECIFICATIONS 2.1

Table 2-1. Capacities
FUEL TANK
TOTAL
gal. liter gal. liter qt. liter oz. liter oz. liter oz. liter
5.2 19.68 1.1 4.16 3.0 2.84 24 0.71 26 0.77 11.5 0.34
FUEL TANK
RESERVE
OIL TANK
W/FILTER
TRANSMISSION
(APPROX.)
PRIMARY
CHAINCASE
FRONT FORKS
Table 2-2. Dimensions
WHEELBASE
in. mm in. mm in. mm in. mm in. mm in. mm in. mm
63.5 1612.9 91.6 2326.6 33.5 850.9 5.5 139.7 47.5 1206.5 31.0 787.4 28.0 711.2
OVERALL
LENGTH
OVERALL
WIDTH
ROAD
CLEARANCE
OVERALL
HEIGHT
SADDLE HEIGHT
Solo Seat
Frame Mount
Seat
Table 2-3. Weight
DRY WEIGHT
lb. kg lb. kg lb. kg lb. kg
697.4 316.3 1200.0 544.3 460.0 208.6 740.0 335.7
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.
GVWR GAWR FRONT GAWR REAR
Table 2-4. Tire Data
TIRE LOCATION SIZE
Front MT9019 Dunlop D402F PT 30 psi (206 kPa) Rear MT90B16 Dunlop D402 PT 36 psi (248 kPa)
MANUFACTURER’S
DESIGNATION
TIRE PRESSURE (Cold)
2003 Dyna Police: Chassis 2-1
Page 12
HOME

TORQUE VALUES 2.2

ITEM
Footboard mounting nuts 84-108 Footboard support mounting
bolts Front seat mounting nut 120-216 Lower engine guard mounting
nuts Pursuit lamp mounting bracket
screw Radio mounting bracket screws 12-18 ft-lbs 16.3-24.4 Nm page 2-14 Rear seat mounting nuts 12-18 ft-lbs 16.3-24.4 Nm page 2-4 Saddlebag guard mounting nut 25-30 ft-lbs 33.9-40.7 Nm page 2-6 Saddlebag guard mounting
screw Saddlebag mounting acorn nut 96-120 Shock mount stud nut 25-30 ft-lbs 33.9-40.7 Nm page 2-6 Tu rn signal mounting nut 12-15 ft-lbs 16.3-20.3 Nm page 2-6
25-35 ft-lbs 33.9-47.5 Nm page 2-12
18-22 ft-lbs 24.4-29.8 Nm page 2-12
30-35 ft-lbs 40.7-47.5 Nm page 2-10
12-18 ft-lbs 16.3-24.4 Nm page 2-6
TORQUE NOTES
in-lbs
in-lbs
in-lbs
9.5-12.2 Nm page 2-12
13.6-24.4 Nm page 2-4
10.8-13.6 Nm page 2-6
2-2 2003 Dyna Police: Chassis
Page 13
HOME

VEHICLE IDENTIFICATION NUMBER 2.3

GENERAL

See Figure 2-1. A 17-digit serial number, or Vehicle Identifica­tion Number (V.I.N.), is stamped on the top of the right front frame downtube. A label bearing the V.I.N. number is affixed to the right front frame downtube.
Market Designation
Manufacturer and Make
Motorcycle Type
Model Designation
Engine
Harley-Davidson
V= Twin Cam 88TM (Carbureted)
An abbreviated V.I.N. is stamped on the left side crankcase at the base of the cylinders.
NOTE
Always give the complete 17 digit V.I.N. when ordering parts or making inquiries about your motorcycle.
1=Domestic 5=International
1=Heavyweight
GK = FXDP
Varies: 1-8
Model Year
K=Manufactured in Kansas City, MO
3=2003
Sequential Number
1HD1GK V 1* 3 K 100000 *Varies - can be 0-9 or X
Sample V.I.N. as it appears on the steering head - 1HD1GKV103K100000 Sample abbreviated V.I.N. as it appears on the left side crankcase - GKV3100000
Figure 2-1. Vehicle Identification Number (V.I.N.)
2003 Dyna Police: Chassis 2-3
Page 14
HOME

SEAT 2.4

REMOVAL

Solo Seat
1. See Figure 2-2. Remove screws (1), washers (2) and nuts (5) from right and left side saddlebag guards.
2. Remove acorn nut (17) and washer (16).
3. Remove fuel tank screw (11) and washer (13) from rod end (12), fuel tank mounting tabs, and frame backbone.
NOTE If switching from solo seat to frame mounted seat, be sure to remove seat cover (26).
Frame Mount Seat
1. See Figure 2-2. Remove screw (23) to detach seat from
fender.
2. Slide seat rearward to remove from frame.

INSTALLATION

Solo Seat
1. See Figure 2-2. Place rod ends (12) over rear fuel tank mounting tabs.
2. Insert screw (11) with washer (13) through rod ends (12), fuel tank mounting tabs, and frame backbone.
3. Loosely install acorn nut (17) and washer (16) on screw (11).
4. Install screws (1), washers (2) and nuts (5) on right and left side saddlebag guards. Tighten nuts to 12-18 ft-lbs (16.3-24.4 Nm).
5. Tighten acorn nut (17) to 120-216
in-lbs
(13.6-24.4 Nm).
Frame Mount Seat
1. See Figure 2-2. Ver ify that seat bracket (24) is securely fastened to bottom of seat. Position seat on frame with bracket at rear.
2. Slide seat forward until tongue on front of seat bottom engages bracket on frame.
3. Install screw (23) to fasten seat bracket to top of rear fender. Tighten mounting bracket screw.
11WARNING1WARNING
After installing seat, pull upward on front of seat to be sure it is locked in position. if seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control and death or serious injury.
4. Pull up on seat to verify that it is locked in place.
2-4 2003 Dyna Police: Chassis
Page 15
HOME
p0080a2x
23
9
8
10
24
25
22
7
6
11
5
20
12
21
19
18
17
16
13
14
15
4
2
1
3
26
1. Screw (2)
2. Washer (2)
3. Right saddlebag guard
4. Spring (2)
5. Nut (2)
6. Nut (2) @12-18 ft-lbs (16.3-24.4 Nm)
7. Washer (2)
8. Screw (2)
9. Seat, solo
10. Seat support bracket
11. Fuel tank screw
12. Rod end (2)
13. Washer
14. Washer
15. Screw @ 18-22 ft-lbs (24.4-29.8 Nm)
16. Washer
17. Acorn nut @ 120-216 in-lbs (13.6-24.4 Nm)
18. Lockwasher (2)
19. Left saddlebag guard
20. Screw (2) @ 18-22 ft-lbs (24.4-29.8 Nm)
21. Nut (2) @ 96-120 in-lbs (10.8-13.6 Nm)
22. Seat, frame mount
23. Screw, frame mount
24. Bracket, seat - frame mount
25. Screw, frame mount (2)
26. Cover seat, plastic - spring mount
Figure 2-2. Seat
2003 Dyna Police: Chassis 2-5
Page 16
HOME

SADDLEBAGS 2.5

REMOVAL

1. See Figure 2-3. Remove acorn nuts (1) and washers (2) from front, middle and rear of saddlebag (16).
2. Remove screws (15) and washers (14) from inside of saddlebag. Note position of washers (7) between saddle­bag and saddlebag guard (3, 17).
3. Remove saddlebag.

INSTALLATION

1. See Figure 2-3. Place saddlebag (16) into position inside saddlebag guards (3, 17).
NOTE In next step, be sure washers (7) are installed in between saddlebag and saddlebag guard.
2. Insert screws (15) and washers (14) through saddlebag
grommets (8) and saddlebag guards.
3. Install acorn nuts (1) and washers (2) at front, middle
and rear of saddlebag (16). Tighten nuts to 96-120 (10.8-13.6 Nm).
in-lbs

SADDLEBAG GUARDS

Installation
1. See Figure 2-3. Place saddlebag mount into position on shock mount stud (25).
2. Loosely install washer (11) screw (12), and saddlebag mount to fender.
3. On left side, insert screw (18) and washer (19) thru left saddlebag guard (17) and upright bracket (22). Install nut (23) and tighten securely.
4. On right side, install washer (31) and nut (32) on screw (27). Tighten to 25-30 ft-lbs (33.9-40.7 Nm).
5. Install nut (30) on shock mount stud (25). Tighten to 25­30 ft-lbs (33.9-40.7 Nm).
6. Tighten screw (12) to 12-18 ft-lbs (16.3-24.4 Nm).
7. Install washer (10) and rubber washer (9) over threads on turn signal (13).
8. Install turn signal thru mounting tab on saddlebag guard.
9. Install lockwasher (5) and nut (4) on turn signal. Tighten nut to 12-15 ft-lbs (16.3-20.3 Nm).
10. Insert wire terminals into connector (6).
11. Connect turn signal connector.
12. Install pole lamp. See 8.5 POLE LAMP.
13. Install saddlebags (16).
14. Connect negative battery cable.
Removal
11WARNING1WARNING
To protect against shock and accidental start-up of vehi­cle, disconnect the negative battery cable before pro­ceeding. Inadequate safety precautions could result in death or serious injury.
1. Disconnect negative battery cable.
2. Remove saddlebag (16).
3. See 8.5 POLE LAMP. Remove pole lamp.
4. See Figure 2-3. Disconnect turn signal connector (6) [18, 19].
5. Remove wire terminals from turn signal connector.
6. Remove nut (4) and washer (5) from turn signal (13).
7. Remove turn signal (13), washer (10) and rubber washer (9) from saddlebag guard (3, 17).
8. Remove nut (30) from shock mount stud (25).
9. On left side, remove screw (18) washer (19) and nut (23) from upright bracket (22).
10. On right side, remove nut (32) and washer (31) from screw (27).
11. Remove screw (12) and washer (11) from rear fender.
12. Remove saddlebag mount.
2-6 2003 Dyna Police: Chassis
Page 17
HOME
p0081a2x
35
39
38
13
1
10
9
5
4
1. Acorn nut (6)
2. Washer (6)
3. Right saddlebag guard
4. Nut (2)
5. Lockwasher (2)
6. Connector (2) [18, 19]
7. Washer (4)
8. Grommet (6)
9. Rubber washer (2)
10. Washer (2)
11. Washer (2)
12. Screw (2)
13. Turn signal (2)
14. Washer (6)
15. Screw (6)
42
41
40
36
37
16
34
15
14
15
8
14
17
8
12
18
11
24
2
7
8
25
26
23
19
33
29
6
3
2
1
16. Saddlebag (2)
17. Left saddlebag guard
18. Screw
19. Washer
20. Screw @ 25-30 ft-lbs
21. Washer
22. Upright bracket
23. Nut
24. Washer (2)
25. Shock mount stud (2)
26. Shock absorber (2)
27. Screw
28. Nut @ 25-30 ft-lbs
30
7
32
(33.9-40.7 Nm)
(33.9-40.7 Nm)
27
28
2
31
22
Motorcycle
frame
20
21
1
29. Washer (2)
30. Nut (2)
31. Washer
32. Nut
33. Spacer
34. Gasket (2)
35. Saddlebag lid (2)
36. Lockwasher, internal (2)
37. Nut (2)
38. Hinge (2)
39. Rivet, blind (32)
40. Tab pull, latch (2)
41. Lock mechanism
42. Key
Figure 2-3. Saddlebags and Saddlebag Guards
2003 Dyna Police: Chassis 2-7
Page 18
HOME

WINDSHIELD 2.6

REMOVAL

1. Cover the front fender with suitable material to protect the fender paint.
2. See Figure 2-4. Loosen, but do not remove, four screws (2) securing mounting brackets (1) to windshield clamps (6).
3. Carefully pull windshield straight forward and up slightly, so that mounting bracket slots (5) clear screws. Remove windshield.

INSTALLATION

1. See Figure 2-4. Lower windshield into position, so that right and left windshield brackets (1) are on the outboard side of windshield clamps (6).
11WARNING1WARNING
Do not replace the screws and washers with ordinary hardware. The screws and washers are designed to main­tain a specific clamping force which other hardware does not provide. Use of other hardware may allow the wind­shield to detach during riding, which can startle the rider and cause loss of vehicle control, which could result in death or serious injury.
2. Slide mounting brackets rearward so screws (2) on wind­shield clamps fit in slots in brackets. Make sure that mounting bracket slots are positioned between flat wash­ers (4) and windshield clamps.
NOTE
In the next step, position windshield so that it does not con­tact headlamp bracket, gauges, pursuit lamp brackets, han­dlebars, or any other part of vehicle.
3. Adjust windshield to desired angle and position. Using a crosswise pattern, tighten all four mounting screws.
4. Turn the front forks to the full left and full right positions to verify that movement is unrestricted.
8857
3
1
2
5
6
1. Windshield mounting bracket (2)
2. Screw (4)
3. Lockwasher (4)
4. Flat washer (4)
5. Adjustment slot
6. Windshield clamp (4)
Figure 2-4. FXDP Windshield Mounting Bracket
4

CARE

CAUTION
Do not clean Lexan® polycarbonate in hot sun or high temperature. Powdered, abrasive or alkaline cleanser will damage the windshield. Never scrape the windshield with a razor blade or other sharp instruments because permanent damage will result. Sunlight reflections off of the inside curvature of a windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windshield to avoid reflections. Harley-David­son windshields are made of Lexan®, a more durable and distortion-resistant material than other types of motorcycle windshield material, But Lexan® still requires attention and care to maintain.
Do not use liquid windshield “protectors” on your
●
windshield. Although they may work well on automo­bile safety glass, Harley-Davidson cannot ensure the results when used on Lexan® Harley-Davidson wind­shields.
Do not use benzene, paint thinner, gasoline, or other
●
types of harsh cleaning agents on windshield. They will damage the windshield surface.
Do not use benzene, paint thinner, gasoline, lubri-
●
cants or other cleaning agents on the rubber bush­ings. They will damage the bushing surfaces.
2-8 2003 Dyna Police: Chassis
Page 19
1. Shoulder screw (7)
2. Shoulder screw (2)
3. Vertical brace (2)
4. Cushion tape (vertical) (2)
5. Outer horizontal brace
6. Windshield
7. Cushion tape (inner horizontal)
8. Inner horizontal brace
9. Mounting bracket (2)
10. Cushion tape (cut to length)
11. Acorn nut (9)
12. Screw (4)
13. Lockwasher (4)
14. Flat washer (4)
15. Screw (4)
16. Windshield clamp (complete) (4)
1
2
3
4
5
6
7
8
9
10
11
12
15
16
13
14
p0114a2x
HOME
Notes
To remove minor surface scratches, use NOVUS® No. 2
●
SCRATCH REMOVER (Part No. 99836-94).
●
If you wish to use a windshield protectant on your wind­shield, use Harley® Glaze Polish and Sealant (Part No. 99701-84).
●
Covering the windshield with a clean, wet cloth for approximately 15-20 minutes before washing will make dried bug removal easier.
1. Use mild soap and warm water to wash the windshield.
2. Wipe dry with a soft, clean towel.
Figure 2-5. Windshield and Brackets
2003 Dyna Police: Chassis 2-9
Page 20
HOME

PURSUIT LAMPS 2.7

MOUNTING BRACKET REPLACEMENT

Removal
11WARNING1WARNING
To protect against shock and accidental start-up of vehi­cle, disconnect the negative battery cable before pro­ceeding. Inadequate safety precautions could result in death or serious injury.
1. Disconnect negative battery cable.
2. Remove fuel tank outer console assembly.
a. Remove the two screws securing the console above
the ignition switch.
b. Remove screw ahead of seat.
c. See Figure 2-6. Lift outer console assembly (1),
removing wiring harnesses (3) from slot (2) in front of outer console.
3. See Figure 2-7. Disconnect pursuit lamp connector [73] (5).
NOTE
Right pursuit lamp is connected to pin 1 of connector [73], and left pursuit lamp is connected to pin 3.
4. Remove wire terminals from pursuit lamp connector shell [73B] using appropriate pick tool (Snap-On TT600-3) according to instructions in the AMP Multilock Electrical Connector section of Appendix B in the Dyna Models Service Manual.
5. Cut any cable straps holding pursuit lamp wiring harness to vehicle, noting position(s) of cable strap(s) and wire harness routing for replacement.
6. See Figure 2-8. Remove screw (7) and lamp mounting bracket (8) with pursuit lamp assembly (1-6).
7. Repeat steps 5-6 for opposite side.
4. Install fuel tank outer console assembly.
a. See Figure 2-6. While lowering outer console
assembly (1) onto fuel tank console, push wiring harnesses (3) into outer console slot (2).
b. Install the two screws above ignition switch and one
ahead of seat. Tighten screws securely.
5. Connect negative battery cable.
8855
3
1
1. Outer console assembly
2. Slot
3. Wiring harnesses
Figure 2-6. FXDP Console Wiring Harnesses
8856
2
1
2
3
4
Installation
1. See Figure 2-8. Mount pursuit lamp mounting bracket (8) to lower triple clamp with screw (7). Tighten to 30-35 ft­lbs (40.7-47.5 Nm). Repeat for opposite side.
2. See Figure 2-7. Route pursuit lamp wiring harnesses up to fuel tank console. Install wire terminals into connector [73] (5).
a. Install wire terminal from right pursuit lamp into pin 1
hole in connector shell.
b. Install wire terminal from left pursuit lamp into pin 3
hole in connector shell.
3. Connect pursuit lamp connector [73]. Secure cable with cable straps.
2-10 2003 Dyna Police: Chassis
5
1. Right handlebar control connector [22]
2. Pursuit lamp flasher connector [69]
3. Left handlebar control connector [24]
4. Ignition switch connector [33]
5. Pursuit lamp connector [73]
Figure 2-7. FXDP Console Connectors
Page 21
HOME
11WARNING1WARNING
p0083b2x
10
7
8
1
2
5
1. Pursuit lamp shell
2. Mounting ring
3. Pursuit lamp bulb (right side - blue, left side - red)
4. Bezel ring
5. Screw (2)
6. Nut (2)
7. Screw (2)
8. Lamp mounting bracket (2)
9. Nut (2)
10. Socket housing
Figure 2-8. FXDP Pursuit Lamp Assembly

HOUSING REPLACEMENT

To protect against shock and accidental start-up of vehi­cle, disconnect the negative battery cable before pro­ceeding. Inadequate safety precautions could result in death or serious injury.
1. Disconnect negative battery cable.
2. See Removal under 2.7 PURSUIT LAMPS, MOUNTING
BRACKET REPLACEMENT. Follow instructions and
remove pursuit lamp and mounting bracket.
9
3
4
6
3. See Figure 2-8. Remove nut (6), screw (5) and bezel ring (4).
4. Loosen screws and disconnect two wire terminals from back of pursuit lamp bulb (3).
5. Pull GY/BK wire through plastic conduit and pursuit lamp housing (1).
6. Remove nut (9) securing pursuit lamp housing to mount­ing bracket (8).
7. Install new pursuit lamp housing onto mounting bracket and secure with nut.
8. Temporarily mount pursuit lamp housing and mounting bracket on lower triple clamp and check that housing points straight ahead when vehicle is upright with front fork pointing straight. If housing is not straight, loosen nut and readjust housing, then retighten nut.
9. Push GY/BK wire through pursuit lamp housing, mount­ing bracket and plastic conduit.
10. See Installation under 2.7 PURSUIT LAMPS, MOUNT-
ING BRACKET REPLACEMENT. Follow instructions
and install pursuit lamp and mounting bracket.
11. Connect two wire terminals to pursuit lamp bulb.
12. Install pursuit lamp bulb in pursuit lamp housing. Make certain to install mounting ring (2) between bulb and housing. Install bezel ring. Secure with nut and screw.
13. Connect negative battery cable.

BULB REPLACEMENT

11WARNING1WARNING
To protect against shock and accidental start-up of vehi­cle, disconnect the negative battery cable before pro­ceeding. Inadequate safety precautions could result in death or serious injury.
1. Disconnect negative battery cable.
2. See Figure 2-8. Remove nut (6), screw (5) and bezel ring (4).
3. Loosen screws and disconnect two wire terminals from back of pursuit lamp bulb (3).
4. Connect two wire terminals to new pursuit lamp bulb.
5. Install pursuit lamp bulb in pursuit lamp housing (1). Make certain to install mounting ring (2) between bulb and housing. Install bezel ring. Secure with nut and screw.
6. Connect negative battery cable.
2003 Dyna Police: Chassis 2-11
Page 22
HOME

FOOTBOARDS 2.8

REMOVAL

Left Side, Footboard Only
1. See Figure 2-9. Remove two screws (8) and nuts (11) securing footboard (14) to footboard support brackets (13 and 18).
2. Remove footboard from brackets.
Right Side, Footboard Only
1. See Figure 2-9. Remove two screws (8) and nuts (11) securing footboard (12) to footboard support brackets (10 and 23).
2. Remove footboard from brackets.
Left Side Footboard Assembly
1. See Figure 2-9. Remove screw (15), washer (16) and nut (19) securing left engine guard mount (17) to left front footboard support (18).
2. Remove bolts (6) and lockwashers (7) securing left front footboard support (18) and left rear footboard support (13) to frame.
Right Side Footboard Assembly
1. See Figure 2-9. Remove cotter pin (3) and washer (2) from clevis pin (1).
2. Remove clevis pin from push rod (5).
3. Remove screw (29), washer (30) and nut (31) securing right engine guard mount (24) to right front footboard support (23).
4. Remove bolts (6) and lockwashers (7) securing right front footboard support (23) and right rear footboard sup­port (10) to frame.

INSTALLATION

Left Side, Footboard Only
1. See Figure 2-9. Mount footboard (14) to footboard sup­port brackets (13 and 18) with two screws (8) and nuts (11).
2. Tighten nuts to 84-108 in-lbs (9.5-12.2 Nm).
Right Side, Footboard Only
1. See Figure 2-9. Mount footboard (12) to footboard sup­port brackets (10 and 23) with two screws (8) and nuts (11).
2. Tighten nuts to 84-108 in-lbs (9.5-12.2 Nm).
Left Side Footboard Assembly
1. See Figure 2-9. Secure left rear footboard support (13) and left front footboard support (18) to frame.
a. Install bolts (6) and lockwashers (7). b. Tighten bolts to 25-35 ft-lbs (33.9-47.5 Nm).
2. Secure left engine guard mount (17) to left front foot­board support.
a. Install screw (15), washer (16), and nut (19). b. Tighten nut to 18-22 ft-lbs (24.4-29.8 Nm).
Right Side Footboard Assembly
1. See Figure 2-9. Secure right rear footboard support (10) and right front footboard support (23) to frame.
a. Install bolts (6) and lockwashers (7). b. Tighten bolts to 25-35 ft-lbs (33.9-47.5 Nm).
2. Secure right engine guard mount (24) to right front foot­board support (23).
a. Install screw (29), washer (30), and nut (31). b. Tighten nut to 18-22 ft-lbs (24.4-29.8 Nm).
3. Install push rod (5) over mounting hole in brake pedal (4).
4. Push clevis pin (1) through push rod and brake pedal.
5. Install washer (2) and cotter pin (3).
2-12 2003 Dyna Police: Chassis
Page 23
HOME
p0101a2x
14
12
11
10
7
7
6
9
4
27
28
5
3
2
1. Clevis pin
2. Washer
3. Cotter pin
4. Brake pedal
5. Push rod
6. Bolt (8) @ 25-35 ft-lbs (33.9-47.5 Nm)
7. Lockwasher (8)
8. Screw (4)
9. Nut
10. Right rear footboard support
11. Nut (4)@ 84-108 in-lbs (9.5-12.2 Nm)
12. Right footboard
13. Left rear footboard support
14. Left footboard
15. Screw
16. Washer
11
26
11
6
7
13
11
8
6
8
7
7
8
20
21
19
25
22
22
6
18
15
16
17
31
7
6
30
29
1
17. Left engine guard mount
18. Left front footboard support
19. Nut @ 18-22 ft-lbs (24.4-29.8 Nm)
20. Washer
21. Nut @ 30-35 ft-lbs (40.7-47.5 Nm)
22. Bushing
23. Right front footboard support
24. Right engine guard mount
25. Wave washer
26. Pivot shaft
27. Washer
28. Screw @ 30-35 ft-lbs (40-7-47.5 Nm)
29. Screw
30. Washer
31. Nut @ 18-22 ft-lbs (24.4-29.8 Nm)
23
8
24
Figure 2-9. Footboards
2003 Dyna Police: Chassis 2-13
Page 24
HOME

RADIO MOUNTING BRACKET 2.9

REMOVAL

1. Remove pole lamp. See 8.5 POLE LAMP.
2. See Figure 2-10. Remove screws (2), washers (3) and nuts (4) securing radio mounting bracket (1) to fender.

INSTALLATION

1. Place radio mounting bracket (1) in place over fender rails (5).
2. Install screws (2), washers (3) and nuts (4). Tighten screws to 12-18 ft-lbs (16.3-24.4 Nm).
3. Install pole lamp. See 8.5 POLE LAMP.
p0102x2x
1
2
5
1. Radio mounting bracket
2. Screw @ 12-18 ft-lbs (16.3-24.4 Nm)
3. Washer
4. Nut
5. Fender rails
3
5
4
Figure 2-10. Radio Mounting Bracket
2-14 2003 Dyna Police: Chassis
Page 25
ENGINE 3
able Of Contents
T
NOTE
All service information in the Dyna Models Service Manual applies to the FXDP police model motorcycle.
Page 26
Page 27
able Of Contents
T
FUEL SYSTEM 4
SUBJECT PAGE NO.
4.1 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
NOTE
This section provides information unique to the FXDP police model motorcycles. Any infor­mation not presented in this supplement can be found in the Dyna Models Service Man­ual.
Page 28
Page 29
HOME
8856
1. Right handlebar control connector [22]
2. Pursuit lamp flasher connector [69]
3. Left handlebar control connector [24]
4. Ignition switch connector [33]
5. Pursuit lamp connector [73]
3
4
1
5
2

FUEL TANK 4.1

REMOVAL

1WARNING1WARNING
Gasoline is extremely flammable and highly explosive. Always stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near the work site. Inadequate safety precautions could result in death or serious injury.
p0117x4x
4
1
2
NOTE
For instructions on properly draining fuel from the fuel supply valve filter, refer to the Dyna Models Service Manual.
8. Drain fuel into adequately sized, approved gasoline con­tainer.
9. See Figure 4-3. Disconnect crossover hose (16) from one end only.
10. Disconnect continuous venting vent line (17) from fitting on fuel tank.
11. Remove front mounting bolt (14), acorn nut (32) and flat washers (13).
12. Remove rear mounting bolt (11), acorn nut (32) and flat washers (13).
NOTE
For instructions on properly disconnecting and connecting the fuel gauge, see 8.15 FUEL GAUGE.
13. Disconnect fuel gauge connector [117] located under left side of fuel tank (12).
14. Remove fuel tank from motorcycle.
H
a
3
1. Console outer assembly
2. Console
3. Fuel tank
4. Screw (3)
Figure 4-1. FXDP Console Assembly
1. If necessary, remove microphone from jack connection on console.
2. See Figure 4-1. Remove console outer assembly (1). a. Remove the two screws (4) on the console above
the ignition switch.
b. Remove screw (4) ahead of seat.
For instructions on properly removing and installing Deutsch electrical connector wire terminals, refer to the Dyna Models Service Manual.
3. See Figure 4-2. Disconnect wire harness connectors (1, 2, 3, 4 and 5).
4. Remove windshield. See 2.6 WINDSHIELD.
5. See Figure 4-3. Verify fuel supply valve (24) is in OFF position.
6. Remove fuel line hose (22) from the fuel supply valve.
7. Remove vacuum hose (28) from fuel supply valve.
r
l
e
y
-
D
NOTE
a
v
i
d
s
o
n
Figure 4-2. FXDP Console Connectors
2003 Dyna Police: Fuel System 4-1
Page 30
HOME
p0103a4x
32
213 4
6
4
4
8
10
7
5
9
11
12
33
13
13
14
13
31
30
29
1. Screw (4)
2. Ignition switch
3. Nameplate
4. Screw (4)
5. Washer
6. Console outer assembly
7. Gasket
8. Console assembly
9. Clip flasher
10. Rivet
11. Bolt
12. Fuel tank
13. Washer (4)
14. Bolt
15. Clamp (4)
16. Hose
15
16
H
a
r
l
e
y
-
D
a
v
i
d
s
o
n
27
32
13
17
18
26
25
19
28
15
21
20
24
23
22
17. Vent line
18. Vapor valve
19. Vapor valve clip
°
20. 90 Elbow
21. Vent line connector
22. Hose (valve to carb.)
23. Insulator
24. Fuel supply valve
25. Fuel filter gasket
26. Nut
27. Filter
28. Hose (vacuum carb.)
29. Decal (2)
30. Filler cap gasket
31. Filler cap
32. Acorn nut
33. Nut Clip
4-2 2003 Dyna Police: Fuel System
Figure 4-3. Fuel Tank Assembly
Page 31
HOME

CLEANING AND INSPECTION

1WARNING1WARNING
Use only non-ferrous (non-sparking) metal balls, such as lead pellets, to loosen deposits. Metal balls, such as steel ball bearings, could produce a spark igniting the fumes in the tank. The resulting flames or explosion could result in death or serious injury.
1. Clean the tank interior with commercial cleaning solvent or a soap and water solution. Shake the tank to agitate the cleaning agent. If necessary, non-ferrous metallic balls or pellets may be added to the tank to assist in loosening deposits.
NOTE Be sure to count the number of pellets going into the tank and the number that come out. An extra pellet in the tank could cause fuel delivery problems.
2. Flush the tank thoroughly after cleaning and allow it to air
dry.
1WARNING1WARNING
Extreme caution should be taken when repairing tanks. If all traces of fuel are not purged, an open flame repair may result in a tank explosion which could result in death or serious injury.
3. Inspect the crossover hose, continuous venting system
vent line (if applicable) and fuel line for cuts, cracks or holes. Replace lines as needed.
4. Inspect the tank for leaks and other damage. If tank is
damaged,
replace
it.

INSTALLATION

PART NO. SPECIALTY TOOL
HD-97087-66B Hose clamp pliers
1. See Figure 4-3. Install fuel tank (12).
2. Install continuous venting system vent line (17) to fitting on fuel tank.
3. Connect the fuel line hose (22) to fuel supply valve (24) located under left side of fuel tank; Install clamp (15) using HOSE CLAMP PLIERS (Part No. HD­97087-66B).
4. Connect vacuum hose (28) to fuel supply valve (24).
5. Install the front mounting bolt (14), flat washers (13), and acorn nut (32).
6. Install rear mounting bolt (11), flat washers (13), and acorn nut (32).
7. Tighten acorn nuts (32) to 120-216 Nm).
NOTE
For instructions on properly disconnecting and connecting the fuel gauge, see 8.15 FUEL GAUGE.
8. Connect fuel gauge connector.
NOTE
For instructions on properly removing and installing Deutsch electrical connector wire terminals, refer to the Dyna Models Service Manual.
9. See 2.6 WINDSHIELD. Install windshield.
10. See Figure 4-2. Connect wire harness connectors (1, 2, 3, 4 and 5).
11. See Figure 4-1. Install console outer assembly (1). a. Install the two screws (4) above ignition switch and
one (4) ahead of seat.
b. Tighten and secure.
12. Connect microphone to jack connection on console.
13. See Figure 4-3. Verify fuel supply valve (24) is in OFF position.
14. Fill tank and check for leaks.
in-lbs
new
hose
(13.6-24.4
2003 Dyna Police: Fuel System 4-3
Page 32
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NOTES

4-4 2003 Dyna Police: Fuel System
Page 33
able Of Contents
T
ELECTRIC STARTER 5
NOTE
All service information in the Dyna Models Service Manual applies to the FXDP police model motorcycle.
Page 34
Page 35
T
able Of Contents
NOTE
All service information in the Dyna Models Service Manual applies to the FXDP police model motorcycle.
DRIVE 6
Page 36
Page 37
T
able Of Contents
NOTE
All service information in the Dyna Models Service Manual applies to the FXDP police model motorcycle.
TRANSMISSION 7
Page 38
Page 39
able Of Contents
T
SUBJECT PAGE NO.
8.1 Bulb Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Rear Marker Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Pole Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6 Siren and Public Address System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.7 Siren/Speaker and Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.8 Handlebar Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.9 Siren Amplifier and Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.10 Adjusting Whelen 100 Watt Siren Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.11 Microphone and Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.12 Enabling Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.13 Electrical Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.14 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.15 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
NOTE
This section provides information unique to the FXDP police model motorcycle. Any informa­tion not presented in this supplement can be found in the Dyna Models Service Manual.
ELECTRICAL 8
Page 40
Page 41
HOME

BULB CHARTS 8.1

GENERAL

Refer to Ta bl e 8-1. The bulb chart lists the light bulbs and LED assemblies used on FXDP police models.
Contact Whelen Engineering for Cycle Signal Lamp replace­ment bulbs. In the United States, dial 203-526-9504.
NOTE
Table 8-1. Bulb Chart
LAMP DESCRIPTION
(ALL LAMPS 12V)
Headlamp
Low beam High beam 5.00 60
Tail and stop lamp
Ta il lamp Stop lamp 2.25*/2.10** 27*/25**
Turn signal lamps
Front turn signal/running lamps 2 2.25/0.59 27/7 68168-89 Rear turn signal 2 2.25 27 68572-64B
Passing/Pursuit lamp
Left (red) 1 Right (blue) 1 68728-64 Rear strobe, if provided 1 N/A 20 67598-88
Instrument Panel/Gauge Lamps
High Beam Indicator 1 Oil Pressure Indicator 1 Neutral Indicator 1 Tu rn Signal Indicator 2 Fuel Gauge‡ Speedometer‡ Odometer‡ Engine‡ Pursuit‡
*
Early 2003 bayonet mount bulb type.
**
Late 2003 wedge mount bulb type.
Illuminated with LEDs and are
NUMBER OF
BULBS
(REQUIRED)
N/A N/A N/A N/A
not
repairable. Assembly must be replaced if LED fails.
CURRENT DRAW
(AMPERAGE)
4.58 55
0.59 7
2.5 30
0.15 2.1 68024-94
WATTAGE
68168-89A*/68167-88
HARLEY-DAVIDSON
PA RT NUMBER
68329-03
68727-64A
**
2003 Dyna Police: Electrical 8-1
Page 42
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TORQUE VALUES 8.2

ITEM
Battery negative cable ground stud
Circuit breaker ring terminal 20-30 Fuel gauge sending unit plate
screws Siren amplifier mounting
bracket screws Siren amplifier mounting
screws Stator mounting screws 55-75 Voltage regulator 60-80
120-180
18-22
60-84
60-84
TORQUE NOTES
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs in-lbs
13.6-20.3 Nm page 8-22, 8-25
2.2-3.4 Nm page 8-22
2.0-2.5 Nm page 8-31
6.8-9.5 Nm page 8-14
6.8-9.5 Nm page 8-14
6.2-8.5 Nm page 8-25
6.7-9.03 Nm page 8-22
8-2 2003 Dyna Police: Electrical
Page 43
HOME
p0065x8x
1. Cover
2. Grommet
3. Bracket
4. Nut
5. Stud
5
4
1
2
3
0
0
Siren
Instruments
Pursuit
P & A
*
Security
Accessories
Ignition
Lights
p0064x8x
*
Turn signal use only.
Security not available on FXDP models.
Police Accessory

FUSES 8.3

GENERAL

Fuses are provided to protect electrical components. To inspect or replace the fuses, carefully follow the procedures below. If an electrical fault occurs after replacement of a fuse, see your Harley-Davidson dealer for service.

SYSTEM FUSES

1. Place the Ignition/Light Key Switch in the OFF position.
2. See Figure 8-1. Pull cover (1) away from electrical panel grommets (2) (no tools required).
NOTE Tw o spare fuses (one 10 amp and one 15 amp) can be found in the relay block at the front of the electrical panel. For fuse ratings and color, refer to Tab l e 8-2.
3. See Figure 8-2. Replace suspect fuse.
NOTE Electrical panel cover has a drain hole. Make sure drain hole is on bottom when installing cover.
4. See Figure 8-1. Push electrical cover (1) onto four grom-
mets (2).
Figure 8-1. Accessing Fuse Block
Table 8-2. Fuses
CIRCUIT
Siren 10 Red Brakes/Pursuit Lamps 15 Blue P& A 10 Red Police Accessory 15 Blue Tu r n Signals 15 Blue Accessory 15 Blue Instruments 15 Blue Ignition 15 Blue Lights 15 Blue
RATING
(AMPERES)
COLOR
Figure 8-2. Fuse Functions
2003 Dyna Police: Electrical 8-3
Page 44
HOME

REAR MARKER LAMP 8.4

GENERAL

The marker lamps combine the filament and blue lens in one integral component. When the filament burns out, the entire lamp is replaced.

REMOVAL

1. See Figure 8-3. Pull pin connector (1) free of pin socket at rear of marker lamp (2).
2. See Figure 8-4. Grasp the lamp (2) and rotate counter­clockwise to free lamp from mounting.

INSTALLATION

1. See Figure 8-4. Insert clockwise to lock in place.
2. See Figure 8-3. Push pin connector (1) into pin socket (3) at rear of lamp.
3. Verify operation of lamps.
new
lamp in opening and turn
p0089x8x
3
1. Pin connector
2. Marker lamp
3. Pin socket
Figure 8-3. Marker Lamp Assembly
4580p
2
1
8-4 2003 Dyna Police: Electrical
Figure 8-4. Marker Lamp Removal/Installation
Page 45
HOME
1. Knurled ring (taper up)
2. Lower bracket
3. Knurled ring (taper down)
2
8247
1
3
8248

POLE LAMP 8.5

GENERAL

Harley-Davidson police motorcycles are shipped from the fac­tory with the brackets necessary to mount a police pole lamp.

Mounting Pole Lamp

1. Cut all but approximately 10.0 in. (254 mm) of wire off the pole lamp.
NOTE
The connector is the type that can only go together one way. Be sure you match the wires correctly. The black wire should go to the black and the green/red wire should go to the red. If wires are not correctly matched, the polarity for the lamp will be wrong and the lamp will not work.
2. Follow directions in the Dyna Models Service Manual Appendix B to terminate connector wires.
3. See Figure 8-6. Unscrew both knurled rings (1, 3) from the pole lamp and slide them off the assembly.
4. See Figure 8-5. Slide the pole lamp through the upper mounting bracket.
8249
Figure 8-5. Upper Mounting Bracket
5. See Figure 8-6. Slide the knurled ring (1) onto the bot­tom of the pole with taper up.
6. Slide the knurled ring (1) and bottom of the pole lamp through lower bracket (2).
a. Screw the knurled ring (3) onto pole from bottom of
lower bracket (2) with taper down.
b. Tighten and secure rings (1, 3) to lock pole in posi-
tion.
c. Snap the wire connector together. d. See Figure 8-7. Use cable straps to secure wire
assembly to pole lamp. Verify wire assembly is not touching saddlebag surface.
Figure 8-6. Pole Lamp Installation
Figure 8-7. Cable Straps
2003 Dyna Police: Electrical 8-5
Page 46
HOME

SIREN AND PUBLIC ADDRESS SYSTEM 8.6

GENERAL

The siren and public address (PA) system consists of: ampli­fier, speaker, microphone, microphone jack, siren, horn/siren switches and connecting wiring.
The Whelen 100 watt siren amplifier, WS-320, (Part No. 91156- 93) uses a waterproof connector [72].
Table 8-3. Troubleshooting
PROBLEM
Siren and PA not operational.
Siren and PA not operational.
Siren functions, PA not operational.
Connector not properly installed. Be sure connector is properly oriented and screw is tight.
Faulty amplifier or speaker. Substitute a known good amplifier and check system func-
PA gain control not properly adjusted.
3.2 Inoperative microphone.
Microphone jack or connecting leads do not provide good electri­cal connection. Wrong microphone.
CAUSE SOLUTION

TROUBLESHOOTING

If siren and/or PA system are inoperative, refer to the follow­ing troubleshooting chart.
Apply wheel bearing grease to connector pins and sockets to reduce corrosion.
tion. If system is still inoperative, substitute a known good speaker and check for system operation.
NOTE
If neither an amplifier nor speaker is available, see 8.7
SIREN/SPEAKER AND MOUNTING BRACKET TROUBLE­SHOOTING. If speaker checks “good”, continue at 8.6 SIREN AND PUBLIC ADDRESS SYSTEM VOLTAGE CHECKS and 8.6 SIREN AND PUBLIC ADDRESS SYS­TEM RESISTANCE AND CONTINUITY CHECKS.
See 8.10 ADJUSTING WHELEN 100 WATT SIREN AMPLI-
FIER.
Substitute a known good microphone. If known good micro­phone is not available, see 8.11 MICROPHONE AND JACK.
See 8.11 MICROPHONE AND JACK.
Some Whelen microphones are electrically different and cannot be interchanged.
8-6 2003 Dyna Police: Electrical
NOTE
Microphones used with WS-320 amplifiers should be marked 010245648-00.
Page 47
HOME

VOLTAGE CHECKS

See Figure 8-8., Refer to Ta ble 8-5., and appropriate wiring diagrams located in the Appendix. Measure the voltages at the motorcycle siren harness connector (pins 1C, 2F, and 1F) as listed in Ta bl e 8-5. The ignition switch must be ON while checking voltages. Connect common or negative lead of volt­meter to a good ground. If voltages specified in Ta b le 8-5. are not present, refer to applicable wiring diagram to diagnose problem.
p0011a8x
Figure 8-8. Pin Connector From Motorcycle Harness
Table 8-4. Pin Connector
From Motorcycle Harness
Pin No.
1A Ground (-) to motorcycle
3A Speaker (+)
1C
3C Speaker (-)
1D
2D Push-to-talk (mic)
1E Mic (-)
1F
2F
3F Mic (+)
12 Vdc supply to amplifier. Present when ignition is on.
Air horn enabled - 12 Vdc is present when connected to horn circuit and but­ton is pushed. See 8.12 ENABLING AIR
HORN.
Yelp, 12 Vdc is present when siren/horn switch is ON.
Wail, 12 Vdc is present when siren switch is ON.
Description/Function
Table 8-5. Voltage Checks at Motorcycle Siren Harness
Switch
Ignition ON 12 Vdc Do Not Measure Do Not Measure
Siren OFF
Siren/Horn ON
Siren ON
Siren/Horn OFF
Siren/Horn ON
Siren ON
Switch
Position
1C 2F 1F
Do Not Measure 0 Vdc 12 Vdc
Do Not Measure 12 Vdc 0 Vdc
Do Not Measure 12 Vdc 12 Vdc
VOLTAGE MEASURED AT PINS
2003 Dyna Police: Electrical 8-7
Page 48
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RESISTANCE AND CONTINUITY CHECKS

See Figure 8-8. Refer to Ta b le 8-6. Perform checks with both battery cables removed.
CAUTION
DO NOT connect ohmmeter probes to a “live” circuit or ohmmeter will be damaged. If ohmmeter readings in
Tabl e 8-6. are not obtained, refer to applicable wiring dia-
gram at rear of this manual to diagnose the problem.
If you do not obtain the ohmmeter readings shown in Ta bl e 8-
6., refer to applicable wiring diagram at rear of this manual to
diagnose the problem.
Table 8-6. Resistance/Continuity Checks (Battery Cables Disconnected)
OHMMETER PROBE LOCATION
(PINS)
3A & 3C 6-10 Ohms
3F & 1E Infinity
Press and hold PTT switch with probes
on pins 2D & 1E.
Common probe to ground, other probe
to pin 1A.
OHMETER
0-1 Ohms
0-1 Ohms Checks amplifier to motorcycle ground.
COMPONENT AND WIRE BEING
CHECKED
Speaker coil voice and leads from pin
connector to speaker.
Verifies microphone circuit is not shorted.
Verifies PTT switch is functioning and two microphone leads from connector have continuity.
See Figure 8-17. for microphone jack connections. To check third lead, place one probe on pin 3F and the other probe on tip terminal of microphone jack.
8-8 2003 Dyna Police: Electrical
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8882
1. Front mounting screw (2)
2. Flat washer (4)
3. Rubber washer (4)
4. Horn
5. Drain hole
6. Cone
7. Locknut (2)
4
1
6
2
5
23
7

SIREN/SPEAKER AND MOUNTING BRACKET 8.7

TROUBLESHOOTING

If siren is inoperative, check voice coil impedance as follows:
1. See Figure 8-9. Disconnect siren connector (1) [57] and measure impedance by connecting ohmmeter leads to siren leads. Measured resistance must be 6-10 ohms.
2. Replace siren if resistance is not within allowable range.
8881
1
3
4
1. Siren connector [57]
2. Siren driver
3. Mounting bracket
4. Rear mounting screw
5. U-bolt (2)
6. Engine guard
2
6
5

REMOVAL

Siren
1. See Figure 8-9. Disconnect siren connector [57] (1). Cut any cable straps securing siren wiring to engine guard.
2. See Figure 8-10. Remove self-locking nuts (7) from front mounting screws (1) at the side and top of the siren horn (4). Remove screws, flat washers (2) and rubber wash­ers (3), and retain for reuse.
3. See Figure 8-9. Remove rear mounting screw (4) from back of mounting bracket (3) and remove siren.
Mounting Bracket
1. See Figure 8-9. Remove locknuts from u-bolts (5).
2. Remove u-bolts and mounting bracket (3) from engine guard (6).
Figure 8-9. Siren and Mounting Bracket
A binding voice coil or torn speaker cone could also cause siren to be inoperative. To check for these conditions, connect siren to shop stereo. If siren works, it is functional.
NOTE
Figure 8-10. Siren Mounting and Drain Hole Location
2003 Dyna Police: Electrical 8-9
Page 50
HOME

INSTALLATION

Siren
1. See Figure 8-9. Install with rear mounting screw (4). Finger tighten only at this time.
●
See Figure 8-10. Be sure drain hole (5) is facing down to provide good drainage. Rotate siren driver housing until drain hole points straight down.
●
Line up holes in siren horn (4) with holes in mounting bracket. If necessary, unscrew cone (6) and turn horn slightly until holes line up properly. Then hand-tighten cone securely.
2. See Figure 8-10. Secure siren to mounting bracket side and top:
a. Insert each front mounting screw (1) through mount-
ing bracket, a flat washer (2), rubber washer (3) and siren horn (4).
b. Install another rubber washer, flat washer, and lock-
nut (7) on screw. Tighten locknut securely.
3. Tighten rear mounting screw.
new
siren in mounting bracket (3)
NOTES
Mounting Bracket
1. If siren has not been installed on mounting bracket, do so at this time. See siren installation procedure above.
2. See Figure 8-9. Install mounting bracket (3) on right side of engine guard (6).
3. Place u-bolts (5) on engine guard and through mounting bracket holes.
4. Thread locknuts onto u-bolts. Position mounting bracket squarely in corner of right side of engine guard, and tighten locknuts evenly and securely.
5. Connect siren connector [57] (1). Secure siren cable to engine guard with cable straps.
CAUTION
Do not use a high pressure washer near the siren. High pressure washers can force water into the siren, ruining it.
NOTE If siren center cone is removed for easier installation, apply 2­3 drops of Loctite 242 (blue) on center cone threads and tighten cone securely with hand.
8-10 2003 Dyna Police: Electrical
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CAUTION
1. Clutch hand lever
2. Siren wail switch
3. Headlamp switch
4. Turn-left signal switch
5. Horn/Siren yelp switch
p0067x8x
32
5
1
4

HANDLEBAR SWITCHES 8.8

HORN/SIREN YELP SWITCH

Consult the Dyna Models Service Manual for assembly/disas­sembly procedures and general repair procedures.
Removal
1. See Figure 8-11. For disassembly of left side handlebar switches, refer to the Dyna Models Service Manual.
2. From inside the switch housing, carefully cut cable strap to free conduit from the turn signal switch bracket.
3. Remove the Phillips screw (with lockwasher) to release the turn signal switch bracket. Remove the switch assembly from the housing.
4. Remove the two T8 TORX screws and the Phillips screw (with lockwasher) to release the lower bracket. Carefully lift out the bracket so as not to disturb the spring-loaded ramp on the inboard side of the housing.
5. Carefully remove the keycap disengaging slot from hook on ramp.
6. While holding down the ramp, pull both switches from the housing.
7. Cut the wires from the old switches as follows:
Y/BK wire: 1-1/4 in. (31.75 mm)
●
●
O/W wires: 1-7/8 in. (42.63 mm) TN/BK wire: 1-1/2 in. (38.1 mm)
●
8. For general repair procedures, refer to the Dyna Models Service Manual.
●
Replacement Horn/Siren Yelp Switch wires are cut to length and partially stripped (Yellow/Black wire: 3-3/4 in. (95.25 mm); Orange/White wires: 3-1/2 in. (88.9 mm); Tan/Black wire: 3-3/8 in. (85.73 mm)).
If the ramp and spring mechanism becomes loose, install
●
as follows: Using the blade of a small screwdriver, com­press spring and place in wider portion of channel at bot­tom of ramp. Verify that spring is evenly compressed and is not cocked or skewed. Push spring so that it bottoms in channel. With tab side of ramp facing inboard and hook end on switch side of casting, install ramp so that narrow channels engage pins cast into housing.
Installation
1. Install the switches in the housing with contacts facing tabs on ramp. For best results, install one switch at a time. Ribs cast in lower housing hold switches in posi­tion.
The Horn switch with the Yellow/Black lead (pivot point towards rider) is installed at the bottom, while the Siren Yelp switch with the Brown/Black lead (pivot point towards the front) is at the top. Route switch wires in channel on the outboard side of the ribbed area.
2. Install the keycap engaging slot with hook on ramp.
3. Install lower bracket sliding pin through keycap and engaging hole in lower casting.
NOTE
Figure 8-11. Left Handlebar Controls
4. Slide T8 TORX screws through holes in lower bracket and switches and thread into lower casting until snug.
5. Install Phillips screw (with lockwasher), to secure lower bracket to threaded boss in housing. Verify operation of Horn and Siren Yelp switches to ensure that both are spring returned.
6. Install Clutch Interlock Switch in bore of lower switch housing, if loose.
7. Insert tapered end of into round hole in turn signal switch bracket and then feed back through using the adjacent hole. Reserve the
NOTES
oblong hole for the bracket screw.
8. Be sure that all splices are positioned above the turn sig­nal switch bracket.
9. Place the turn signal switch assembly into the housing aligning the oblong hole in the bracket with the lower bracket weld nut. Be sure that bracket is fully seated. Ta bs on each side are captured in slots cast into switch housing.
10. Install Phillips screw (with lockwasher) to secure bracket inside housing.
If routed incorrectly, wires may be pinched by casting or handlebar resulting in switch failure.
11. Loop switch wires so that spliced lengths are positioned directly over bracket screw.
12. Capturing conduit about 1/4 in. (6.4 mm) from end, securely tighten cable strap to draw conduit to bracket. Remove any excess cable strap material.
13. On opposite side, install second 7 in. (177.8 mm) cable strap capturing conduit and wire splices. Securely tighten cable strap to draw splices to conduit. Remove any excess cable strap material.
14. Route wire bundle to upper switch housing below and then forward of the main wire harness positioning conduit in channel next to angular arm of bracket. Secure bundle to arm placing
new
7 in. (177.8 mm) cable strap
new
cable strap 1/4 in. (6.4 mm) from end
2003 Dyna Police: Electrical 8-11
Page 52
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of conduit. Cut any excess cable strap material. If neces­sary, bend angular arm of bracket downward to firmly secure Clutch/Starter Interlock Switch in installed posi­tion.
15. For assembly of left side handlebar switches, refer to the Dyna Models Service Manual.

CLUTCH INTERLOCK SWITCH

NOTE
All Police models have a clutch/starter interlock that prevents the motorcycle from being started unless the clutch lever is pulled in.
Removal
1. For disassembly of left side handlebar switches, refer to the Dyna Models Service Manual.
2. From inside the switch housing, carefully cut cable strap to free conduit from the turn signal switch bracket.
CAUTION
If routed incorrectly, wires may be pinched by casting or handlebar resulting in switch failure.
5. Loop switch wires so that spliced lengths are positioned directly over bracket screw.
6. Capturing conduit about 1/4 in. (6.4 mm) from end, securely tighten cable strap to draw conduit to bracket. Remove any excess cable strap material.
7. On opposite side, install second 7 in. (177.8 mm) cable strap capturing conduit and wire splices. Securely tighten cable strap to draw splices to conduit. Remove any excess cable strap material.
8. Route wire bundle to upper switch housing below and then forward of the main wire harness positioning conduit in channel next to angular arm of bracket. Secure bundle to arm placing new cable strap 1/4 in. (6.4 mm) from end of conduit. Cut any excess cable strap material. If neces­sary, bend angular arm of bracket downward to firmly secure clutch interlock switch in installed position.
9. For assembly of left side handlebar switches, refer to the Dyna Models Service Manual.
3. Remove the Phillips screw (with lockwasher) to release the turn signal switch bracket. Remove the switch assembly from the housing.
4. Remove the clutch interlock switch from the housing.
5. Cut wires 1/4 in. (6.4 mm) from old switch. Discard switch assembly.
6. For general repair procedures, refer to the Dyna Models Service Manual.
Installation
NOTE
Replacement Clutch Interlock Switch wires are cut to length (looking at backside, left side switch wire is 2-1/4 in. (57.2 mm), right side is 2-3/4 in. (69.9 mm)) and partially stripped.
1. See Figure 8-12. Install clutch interlock switch in bore of lower switch housing.
2. Insert tapered end of into round hole in turn signal switch bracket and then feed back through using the adjacent hole. Reserve the oblong hole for the bracket screw.
Be sure that all splices are positioned above the turn signal switch bracket.
3. Place the turn signal switch assembly into the housing aligning the oblong hole in the bracket with the lower bracket weld nut. Be sure that bracket is fully seated. Tabs on each side are captured in slots cast into switch housing.
4. Install Phillips screw (with lockwasher) to secure bracket inside housing.
new
7 in. (177.8 mm) cable strap
NOTE

PURSUIT/AUXILIARY SWITCH

Removal
1. For disassembly of right side handlebar switches, refer to the Dyna Models Service Manual.
2. From inside the switch housing, carefully cut cable strap to free conduit from the turn signal switch bracket.
3. Remove the Phillips screw (with lockwasher) to release the turn signal switch bracket. Remove the switch assembly from the housing.
4. Remove the two T8 TORX screws and the Phillips screw (with lockwasher) to release the lower bracket. Remove the bracket from the housing.
5. Pull both switches from the housing.
6. Cut the wires from the old switches as follows:
● GY/BK wire: 1-1/2 in. (38.1 mm)
● O/V wires: 1-3/8 in. (34.93 mm)
● GN/R wire: 1-1/4 in. (31.75 mm)
NOTE Replacement pursuit/auxiliary switch wires are cut to length and partially stripped (Gray/Black wire: 2.0 in. (51 mm); Orange/Violet wires: 1-7/8 in. (42.63 mm); Green/Red wire: 1­3/4 in. (44.5 mm)).
7. For general repair procedures, refer to the Dyna Models
Service Manual.
8. Move keycap to the OFF position. Install the switches in
the housing with contacts facing the recessed area on the ramp. Ribs cast in lower housing hold switches in position.
9. The auxiliary switch with the GY/BK lead is installed at
the bottom, while the Pursuit switch with the GN/R lead is at the top. Route switch wires into corner space outside of the ribbed area.
8-12 2003 Dyna Police: Electrical
Page 53
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p0069x8x
p0040ax8x
Figure 8-12. Lower Switch Housing
NOTE
If the keycap and ramp mechanism requires replacement, install as follows:
a. Slide ramp upward to remove from keycap shaft. b. Remove keycap from switch housing. c. Install spring into hole on inboard side of new key-
cap.
d. Position ball on end of spring. Use a small amount of
grease to hold ball in place.
e. Install keycap so that ball engages detente in switch
housing.
f. Slide ramp over keycap shaft so that tongues on
ramp engage grooves in keycap shaft.
CAUTION
If routed incorrectly, wires may be pinched by casting or handlebar resulting in switch failure.
7. Loop switch wires so that spliced lengths are positioned directly over bracket screw.
8. Capturing conduit about 1/4 in. (6.4 mm) from end, securely tighten cable strap to draw conduit to bracket. Remove any excess cable strap material.
9. On opposite side, install second 7 in. (177.8 mm) cable strap capturing conduit and wire splices. Securely tighten cable strap to draw splices to conduit. Remove any excess cable strap material.
10. Route wire bundle to upper switch housing in channel next to angular arm of bracket. Secure bundle to arm placing new cable strap 1/4 in. (6.4 mm) from end of con­duit. Cut any excess cable strap material. If necessary, bend angular arm of bracket downward to firmly secure front stoplight switch in installed position.
11. For assembly of right side handlebar switches, refer to the Dyna Models Service Manual.
Installation
1. Install lower bracket with the weld nut side down.
2. Slide the T8 TORX screws through holes in lower bracket and switches and thread into lower casting until snug.
3. Install Phillips screw (with lockwasher), to secure lower bracket to threaded boss in housing. Work auxiliary and pursuit switches to ensure smooth operation.
4. See Figure 8-13. Insert tapered end of new 7 in. (177.8 mm) cable strap into round hole in turn signal switch bracket and then feed back through using the adjacent hole. Reserve the oblong hole for the bracket screw.
NOTE
Be sure that all splices are positioned above the turn signal switch bracket.
5. Place the turn signal switch assembly into the housing aligning the oblong hole in the bracket with the lower bracket weld nut. Be sure that bracket is fully seated. Tabs on each side are captured in slots cast into switch housing.
6. Install Phillips screw (with lockwasher) to secure turn sig­nal switch bracket inside housing.
Figure 8-13. Cable Strap Through Right Turn Signal Switch
2003 Dyna Police: Electrical 8-13
Page 54
HOME

SIREN AMPLIFIER AND MOUNTING BRACKET 8.9

GENERAL

Table 8-7. Component Identification
Part No. Description
91156-93 Whelen - 100 watt (WS-320)
76006-03 Amplifier mounting kit
See Figure 8-14. The Whelen amplifier (1) is mounted to the amplifier mounting bracket (2) under the left saddlebag guard (3).

REMOVAL

Remove left saddlebag. See REMOVAL under 2.5 SADDLE-
BAGS.
Amplifier
1. See Figure 8-14. Pull back rubber boot (4) covering amplifier harness connector [72] (5).
2. Loosen connector screw and disconnect harness con­nector.
3. Remove four mounting screws, nuts and washers (6). Remove amplifier from vehicle.
2. Mount amplifier to amplifier mounting bracket with four mounting screws, nuts and washers (6). Tighten screws to 60-84 in-lbs (6.8-9.5 Nm).
3. Plug in harness connector [72] (5) and tighten connector screw.
4. Install rubber boot (4) on harness connector.
5. Install left saddlebag. See INSTALLATION under 2.5
SADDLEBAGS.
8868
3
2
6
4
1
5
1. Whelen amplifier
2. Amplifier mounting bracket
3. Saddlebag guard
4. Rubber boot
5. Harness connector [72] (inside rubber boot)
6. Mounting screws (4), nuts (4), and washers (4)
Mounting Bracket
1. See Figure 8-15. Remove three locknuts (5), washers (4) and countersunk machine screws. Remove mounting bracket.
2. Remove three p-clamps (3) from saddlebag guard rails (2).

INSTALLATION

Mounting Bracket
1. See Figure 8-15. Secure amplifier mounting bracket (1) to underside of left saddlebag guard rails (2) with three p-clamps (3), countersunk machine screws, washers (4) and locknuts (5) as shown. Make sure amplifier mounting bracket is placed in position with three tapered holes fac­ing down.
2. Tighten screws to 60-84 in-lbs (6.8-9.5 Nm).
Amplifier
1. See Figure 8-14. Position Whelen amplifier (1) on under­side of amplifier mounting bracket (2) with amplifier con­nector socket facing front of vehicle.
NOTE When performing the following step, make sure the screw heads and washers are on the amplifier side of the mounting bracket.
Figure 8-14. Whelen Amplifier Mounting
8866
2
5
4
1. Amplifier mounting bracket
2. Saddlebag guard rail
3. P-clamp (3)
4. Washer (3)
5. Locknut (3)
Figure 8-15. Amplifier Mounting Bracket
3
1
8-14 2003 Dyna Police: Electrical
Page 55
HOME
4575p

ADJUSTING WHELEN 100 WATT SIREN AMPLIFIER 8.10

GENERAL

The public address (PA) amplifier gain is set by the manufac­turer and normally does not require adjustment. If it has feed­back, low volume or distortion, adjust the gain as follows:
Gain Adjustment
1. See Figure 8-16. Remove gain adjustment access screw to expose the internal adjusting screw.
2. Press push-to-talk (PTT) switch on microphone, speak into microphone in normal manner and while speaking, carefully turn internal adjusting screw to obtain maximum distortion free output.
3. Replace gain adjustment access screw.
Figure 8-16. PA Gain Adjustment Access Screw
2003 Dyna Police: Electrical 8-15
Page 56
HOME

MICROPHONE AND JACK 8.11

MICROPHONE

Troubleshooting
1. See Figure 8-17. To verify that push-to-talk (PTT) switch is functioning properly, connect probes of ohmmeter to tip and ring of microphone plug.
2. With PTT switch off (not depressed) there must be no continuity.
3. Depress PTT switch. Ohmmeter must read 0-1 ohm. Replace microphone if there is no continuity.

MICROPHONE JACK

Removal
1. The jack is mounted on the left side of the fuel tank con­sole.
p0013a8x
2
3
2. Remove fuel tank console. a. Remove the two screws on the console above the
ignition switch.
b. Remove screw ahead of seat.
3. Remove nut and washer from jack.
4. Remove fuel filler cap, gently lift console and remove jack.
5. Unsolder leads from jack terminals.
Installation
1. See Figure 8-17. Solder leads to jack terminals as shown.
2. Install jack and secure with washer and nut.
3. Replace all parts removed to gain access to jack.
R
W
To Pin Connector
1
1. Sleeve
2. Ring
3. Tip
4. Microphone jack
5. Microphone plug
2
BE
1
3
4
5
Figure 8-17. Microphone and Jack Connections
8-16 2003 Dyna Police: Electrical
Page 57
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8856
1. Right handlebar control connector [22]
2. Pursuit lamp flasher connector [69]
3. Left handlebar control connector [24]
4. Ignition switch connector [33]
5. Pursuit lamp connector [73]
3
4
1
5
2
O/W
K
K
K
K
[
]
(
)
CLUTCH
CH
S
CH
CH
CH
N
SWITCH
C
Y
N
'
D
ROM
SS
]
[
]
CO
S

ENABLING AIR HORN 8.12

PROCEDURE

1. Remove fuel tank console. a. Remove the two screws on the console above the
ignition switch.
b. Remove screw ahead of seat.
NOTE For instructions on properly removing and installing Deutsch electrical connector wire terminals, refer to the Dyna Models Service Manual.
2. See Figure 8-18. Disconnect left handlebar control con-
nector [24] (3). a. See Figure 8-19. Pull seal pin from cavity 11 of con-
nector shell [24B]. b. Remove Y/BK wire from cavity 6. c. Install Y/BK wire in cavity 11. d. Push seal pin into cavity 6.
3. Reconnect left handlebar control connector.
4. Install fuel tank console. a. Install the two screws above ignition switch and one
ahead of seat.
b. Tighten and secure.
Figure 8-18. FXDP Console Connectors
p0084x8x
LOCKOUT SWIT
24L
NTROL
MOVE Y/BK WIRE FROM
AVITY 6 TO CAVIT 11 IF USING WHELEN SIRE AMPLIFIER & 'AIR HORN FUNCTION IS DESIRE
WIT
WIT
WIT
RN/SIRE
Y/B
PK/B TN/B
Y/B
24B
GRAY
NE 4A
Figure 8-19. Enabling the Air Horn
2003 Dyna Police: Electrical 8-17
Page 58
HOME

ELECTRICAL CONNECTOR LOCATIONS 8.13

Table 8-8. Wire Harness Connectors
CONNECTOR
NO.
[7] Tail Lamp Harness To Main Harness 8-Place Multilock Under Seat -
[10] Ignition Module (Black) 12-Place Deutsch
[11] Ignition Module (Gray) 12-Place Deutsch
[18] Left Rear Turn Signal 2-Place Multilock Inside Tail Lamp Lens Figure 8-21. [19] Right Rear Turn Signal 2-Place Multilock Inside Tail Lamp Lens Figure 8-21.
[20] Gauges, Indicator Lamps 12-Place Deutsch
[22] Right Hand Controls 12-Place Deutsch Under Console Figure 8-22. [24] Left Hand Controls And Horn 12-Place Deutsch Under Console Figure 8-22. [30] TSM 12-Place Deutsch Electrical Panel Figure 8-23. [38] Headlamp 4-Place Multilock Under Console Cover Figure 8-22. [31] Front Turn Signals 6-Place Multilock Under Console Cover Figure 8-22. [73] Pursuit Lamps 4-Place Multilock Under Console Cover Figure 8-22. [33] Ignition Key Switch 3-Place Packard Under Console Cover Figure 8-22. [39] Speedometer 12-Place Packard Back Of Speedometer -
[46] Voltage Regulator To Stator 2-Place Facon
[65] Speedometer Sensor 3-Place Deutsch Under Seat ­[79] Crank Position Sensor (CKP) 2-Place Mini-Deutsch Under Seat ­[80] Manifold Air Pressure Sensor (MAP) 3-Place Packard Top Of Manifold ­[83] Ignition Coil 3-Place Packard On Back Of Coil -
[91] Data Link Connector 4-Place Deutsch
[93] Tail Lamp 4-Place Multilock Inside Tail Lamp Lens Figure 8-21. [94] Tail Lamp Power In 6-Place Multilock Inside Tail Lamp Lens Figure 8-21.
[108] Tachometer 6-Place Packard Back Of Tachometer -
[117]
[139] Oil Pressure Sending Unit 2-Place Mini-Deutsch Under Seat -
[62] Starter Relay, Brake Relay
[63] Fuse Block Spade Terminals Electrical Panel Figure 8-23.
- Rear Stoplight Switch Spade Terminals
- Main Circuit Breaker Ring Terminals Electrical Panel -
-Starter Solenoid Spade Terminals Top Of Starter -
- Neutral Switch Post Terminals Top Of Transmission -
- Harness Grounds (2) Ring Terminals Under Seat -
Fuel Gauge And Fuel Level Sending Unit
DESCRIPTION TYPE LOCATION Figure
Under Seat, Behind Electrical Panel
Under Seat, Behind Electrical Panel
Inside Frame Back­bone
Front Of Engine Crank­case
T- S t ud On Back Of Electrical Panel
2-Place Multilock
Spade Terminals Fuse/Relay Block
Left Front Side Of Fuel Ta n k
Electrical Panel Figure 8-23.
Behind Rear Master Cylinder
-
-
-
Figure 8-20.
-
-
-
8-18 2003 Dyna Police: Electrical
Page 59
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p0077x8x
1. Tail lamp [93]
2. Fender tip lamp [45]
3. Left turn signal lamp [18]
4. Right turn signal lamp [19]
5. Tail lamp power in [94]
3
1
2
4 5
Table 8-8. Wire Harness Connectors
CONNECTOR
NO.
-Oil Pressure Switch Post Terminal On Oil Pressure Switch ­[69] Pursuit Lamp Flasher Spade Terminals Under Console Cover Figure 8-22. [68] Microphone Jack RCA Jack Left Side Of Console - [59] Pole Lamp 2-Place Deutsch Behind Left Saddlebag Figure 8-24. [72] Siren Amplifier 2-Place Deutsch Under Left Saddlebag Figure 8-25.
[122] Horn Spade Terminal Left Side Of Engine -
[57] Siren/PA Speaker 2-Place Mini-Deutsch
[4] Customer Accessory Connector 2-Place Mini-Deutsch Under Seat -
p0076x8x
DESCRIPTION TYPE LOCATION Figure
Right Side On Engine Guard
1
2
-
4
3
1. Connector clip
2. Stator/Voltage regulator connector [46]
3. Cable strap
4. Right lower frame tube (inboard side)
Figure 8-20. Stator/voltage Regulator Connector
3
Figure 8-21. Rear Fender Lights Assembly
2003 Dyna Police: Electrical 8-19
Page 60
HOME
8856
2
1
5
1. Right handlebar control connector [22]
2. Pursuit lamp flasher connector [69]
3. Left handlebar control connector [24]
4. Ignition switch connector [33]
5. Pursuit lamp connector [73]
Figure 8-22. FXDP Console Connectors
p0087x8x
3
4
p0085x8x
2 3 5 134
1
1. Spare fuses
2. Brake light relay
3. Starter relay [62]
4. TSM/TSSM
5. P&A
6. Accessory
7. Lights
8. Ignition
9. Instruments
10. 4-Way flasher/Turn signals
11. Police accessory
12. Siren
13. Pursuit lamps
Figure 8-24. Pole Lamp Connector
p0088x8x
12
6
7
11
10
9
8
Figure 8-23. Electrical Panel
8-20 2003 Dyna Police: Electrical
Figure 8-25. Whelen Amplifier Mounting Connection
Page 61
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p0091x8x

CHARGING SYSTEM 8.14

GENERAL

The charging system consists of the alternator and regulator. Charging system circuits are as shown. See Figure 8-26.
Alternator
The alternator consists of two main components:
● The rotor which mounts to the engine sprocket shaft.
● The stator which bolts to the engine crankcase.
Voltage Regulator
A series regulator with a circuit that combines the functions of rectifying and regulating.
70103-96
BK

TROUBLESHOOTING

When the charging system fails to charge or does not charge at a satisfactory rate, make the following recommended checks.
Battery
Check for a weak or dead battery. Battery must be fully charged in order to perform any electrical tests.
Wiring
Check for corroded or loose connections in the charging cir­cuit.
Voltage Regulator Inspection
The regulator must have a clean, tight ground connection for proper operation. Check by using an ohmmeter with one lead on the battery ground cable and the other on the regulator ground terminal (on left side ground post in front of battery).
Connector plug at engine crankcase must be clean and tight.
STATO R
STARTER
BATTERY
70102-96
[5]
BK
[46B]
BK
[46A]
CIRCUIT
BREAKER
40 AMP
BK
BK
12
12
COPPER
STUD
BK
BK BK
VOLTAGE
REGULATOR
AC
DC
+
Figure 8-26. Charging System Circuit (Typical)
2003 Dyna Police: Electrical 8-21
Page 62
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VOLTAGE REGULATOR

Removal
1. Remove seat. See 2.4 SEAT.
1WARNING1WARNING
To protect against shock and accidental start-up of vehi­cle, disconnect the negative battery cable before pro­ceeding. Inadequate safety precautions could result in death or serious injury.
2. Unthread bolt and remove battery negative cable (black) from ground stud under plastic seat cover.
3. Remove fuel tank console. a. Remove the two screws on the console above the
ignition switch.
b. Remove screw ahead of seat.
4. See Figure 8-27. Disconnect main wire harness connec­tors (1, 2, 3, 4 and 5).
5. See Figure 8-28. Remove terminal nut from ground post under seat. Remove ring terminal (15).
6. Remove terminal nut from silver post of 40 amp circuit breaker under seat. Remove ring terminal (16).
7. Remove pursuit lamp bracket. See 2.7 PURSUIT
LAMPS.
8. Remove fuel tank. See 4.1 FUEL TANK.
9. See Figure 8-28. Carefully cut cable straps securing ter­minal cables (15, 16) along frame backbone left side.
10. Remove regulator plug cover (9).
11. Disconnect socket housing (7).
12. Remove two screws (14) from voltage regulator (13) and remove voltage regulator from motorcycle.
Installation
1. See Figure 8-28. Attach voltage regulator (13) to motor- cycle frame bracket with two screws (14). Tighten to 60­80 in-lbs (6.7-9.03 Nm).
2. Connect socket housing (7).
3. Install regulator plug cover (9).
4. Attach cable straps and terminal cables (15, 16) through hole in left side of frame back bone.
a. Loop cable strap around terminal cables. b. Loosely push tapered end of cable strap through slot
on opposite end of strap.
c. Firmly push barbed end of cable strap into hole on
left side of frame backbone to anchor.
d. Pull on tapered end of cable strap until terminal
wires are secured to left side of frame backbone.
e. Repeat steps 4.a through 4.d for the next three
holes.
5. Install fuel tank. See 4.1 FUEL TANK.
6. Secure pursuit lamp bracket. See 2.7 PURSUIT LAMPS.
7. See Figure 8-28. Attach ring terminal (16) to silver post of 40 amp circuit breaker under seat. Tighten to 20-30 in-lbs (2.2-3.4 Nm).
8. Attach ring terminal (15) to ground post under seat. Tighten and secure.
9. See Figure 8-27. Connect main wire harness connec­tors.
10. Install fuel tank console. a. Attach the two screws above ignition switch and one
ahead of seat.
b. Tighten and secure.
11. Thread bolt and attach battery negative cable (black) to ground stud. Tighten to 120-180 in-lbs (13.6-20.3 Nm).
1WARNING1WARNING
On FXDP model motorcycles with frame mount seat, after installing seat, pull upward on front of seat to be sure it is locked in position. if seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control and death or serious injury.
12. Install seat. See 2.4 SEAT.
8856
1
2
3
8-22 2003 Dyna Police: Electrical
4
5
1. Right handlebar control connector [22]
2. Pursuit lamp flasher connector [69]
3. Left handlebar control connector [24]
4. Ignition switch connector [33]
5. Pursuit lamp connector [73]
Figure 8-27. FXDP Console Connectors
Page 63
HOME
p0099a8x
3
2
4
1
5
6
17
7
8
9
1. Stator
2. Rotor
3. TORX Screw (4)
4. Spacer
5. Seal cable (4)
6. Terminal socket (2)
7. 2-way socket housing
8. Lock, socket terminal
9. Cover, regulator plug
10. Lock, pin terminal
11. 2-way pin housing
12. Terminal pin (2)
13. Voltage regulator
14. Screw (2)
15. Terminal, 5/16 in ring - internal star
16. Terminal, #10 ring 12-14 ga.
17. Rubber grommet
16
15
14
13
10
11
12
5
Figure 8-28. Alternator and Regulator Assembly
2003 Dyna Police: Electrical 8-23
Page 64
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ALTERNATOR ROTOR/STATOR

Removal/Disassembly
1. Remove seat. See 2.4 SEAT.
1WARNING1WARNING
To protect against shock and accidental start-up of vehi­cle, disconnect the negative battery cable before pro­ceeding. Inadequate safety precautions could result in death or serious injury.
2. Unthread bolt and remove battery negative cable (black) from ground stud under plastic seat cover.
NOTE It is not necessary to remove the inner primary chaincase to remove the alternator.
3. Remove outer primary cover, primary drive and clutch.
Refer to the Dyna Models Service Manual for primary cover, drive and clutch removal procedures.
4. Remove engine sprocket shaft extension. See Figure 8-
28. Remove the alternator rotor spacer (4), if present.
1CAUTION
Since the rotor contains powerful magnets, the ROTOR REMOVER/INSTALLER and SHAFT PROTECTOR SLEEVE (Part No. HD-41771) must be used to prevent parts dam­age and possible hand injury during removal and instal­lation.
5. See Figure 8-29. See Figure 8-30. See Figure 8-31.
Remove rotor as follows: a. Verify that threads of engine sprocket shaft are
clean, especially of old Loctite material. thread Shaft Protector Sleeve onto engine sprocket shaft.
b. Tu rn thumbscrews of Rotor Remover/Installer into
threaded holes in rotor face.
c. Rotate handle of forcing screw in clockwise direction
to remove rotor from engine sprocket shaft.
6. See Figure 8-28. Remove T27 TORX screws (3). Unplug
voltage regulator connector [46B] and remove stator (1).
7. Remove rubber boot and connector [46] from screw on
front engine mount. Slide regulator plug cover (9) off of connector [46] and disconnect Facon connector [46].
8. Remove socket terminal lock (8) and pull wires from con-
nector [46B] (2-way socket housing–7).
NOTE Contact cleaner, alcohol or glass cleaner sprayed on rubber grommet will provide lubrication when pulling grommet through crankcase hole.
9. Move grommet to one side and spray contact cleaner
into gap. Repeat for other side. Pull rubber grommet through crankcase hole.
10. Pull wires through crankcase hole.
p0116x8x
Figure 8-29. Clean Sprocket Shaft Threads.
p0116x8x
Figure 8-30. Install Shaft Protector Sleeve.
p0116x8x
Rotor
Sprocket Shaft
Shaft Protector
1
2
1
1. Thumbscrew
2. Forcing screw
3. Handle Figure 8-31. Install Rotor Remover/Installer.
Rotate Handle in a Clockwise Direction.
Engine
Sleeve
3
8-24 2003 Dyna Police: Electrical
Page 65
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Cleaning/Inspection
Rotor and stator may be replaced individually if either is dam­aged.
1. Remove all foreign particles from rotor magnets.
2. Clean rotor and stator in clean, soapy water.
Assembly/Installation
NOTE
Stator TORX fasteners are not re-usable. They must be replaced.
1. Insert stator wires through crankcase hole.
2. See Figure 8-28. Push rubber grommet (17) through crankcase hole. If necessary, apply the same lubricant used during removal.
3. Insert wires into connector [46B] (2-way socket housing–
7).
4. Install socket terminal lock (8) into connector.
5. Mate connector [46]. Slide regulator plug cover (9) over connector [46] and install connector/plug cover assembly to front engine mount screw.
6. Install stator (1) onto crankcase and fasten in place with new T27 TORX screws. Tighten to 55-75 in-lbs. (6.2-8.5 Nm).
7. Install rotor as follows: a. See Figure 8-29. See Figure 8-30. See Figure 8-31.
Install Shaft Protector Sleeve and Rotor Remover/ Installer, if removed.
NOTE
Shaft Protector Sleeve not only protects engine sprocket shaft threads from rotor splines, but acts as a guide to ensure that rotor is properly centered.
b. Center ball on forcing screw in recess at end of
engine sprocket shaft. Rotate handle of tool in a counterclockwise direction to ease rotor into position over stator.
c. Loosen thumbscrews and remove Rotor Remover/
Installer. Remove Shaft Protector Sleeve.
8. Install alternator rotor spacer (if present) and engine sprocket shaft extension.
9. Install clutch, primary drive and outer primary cover. Refer to the Dyna Models Service Manual for clutch, drive and primary cover installation procedures.
10. Thread bolt and attach battery negative cable (black) to ground stud. Tighten to 120-180 in-lbs (13.6-20.3 Nm).
11. Install seat. See 2.4 SEAT.
2003 Dyna Police: Electrical 8-25
Page 66
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Test (Part 1 of 2)
SYMPTOM: BATTERY BECOMES DISCHARGED
Charge or replace as required.
See REGULATOR INSPECTION.
See Voltage Regulator Inspection.
Test battery.
Inspect regulator.
Inspect regulator.
FAILPASS
Test regulator.
See Regulator Bleed Test.
Perform Milliamp Draw Test
(If applicable).
Perform Total Current Draw Test.
Record measurement.
Correct as
required.
5306
FAILPASS
Replace
regulator.
5307
FAILPASS
Isolate damaged
component or wiring.
FAILPASS
5308
STOP
Go to Test
(Part 2 of 2).
8-26 2003 Dyna Police: Electrical
Isolate damaged wiring or
excessive accessories.
NOTE Whenever a charging system component fails a test and is replaced, re-test the system to be sure the problem has been corrected.
5310
Page 67
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Test (Part 2 of 2)
SYMPTOM: BATTERY BECOMES DISCHARGED
Perform Current and Voltage Output Test. Record
measurement and compare with Total Current Draw
From Test (Part 2 of 2).
Test before proceeding.
FAILPASS
Perform Voltage Output Test.
System tests good up to this point. Suspect:
Accessories on for long periods when vehicle is parked and not running.
Accessories on when vehicle is ridden very slowly for long periods.
Battery self-discharge and/or accessory draw because vehicle was not operated for a long period.
FAILPASS
Replace
regulator.
5316
PASS
System
OK.
Perform AC Output
Check.
Replace regulator.
Perform Current and
Voltage Output Test.
5375
FAIL
Damaged or
slipping rotor.
Perform
Stator Check.
PASS
Replace
stator.
5314
FAILPASS
Replace
stator.
FAILPASS
Inspect rotor.
FAIL
Replace
rotor.
5312
5319
NOTE Whenever a charging system component fails a test and is replaced, re-test the system to be sure the problem has been corrected.
2003 Dyna Police: Electrical 8-27
Page 68
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TESTING

Regulator Bleed Test
Be sure regulator is connected to battery. Unplug stator con­nector. Use a trouble light and touch one probe to a known good ground and the other to the regulator pins, one at a time. If light glows, replace regulator.
Milliamp Draw Test
NOTE
Be sure accessories are not wired so they stay on at all times. Check for this by connecting ammeter between negative bat­tery terminal and battery.
See Figure 8-32. Connect ammeter between negative battery terminal and battery. With this arrangement, you will also pick up any regulator drain.
The limits for these drains are listed in Ta bl e 8-9.
● Any accessories must be considered and checked for
excessive drain.
● This condition could drain battery completely if vehicle is
parked for a long time.
NOTES
● A battery with surface discharge condition or over full
could cause a static drain. Correct by lowering levels in cells and cleaning battery case.
p0092x8x
AMP
Battery
Battery
negative cable
Ignition OFF
Figure 8-32. Milliamp Draw Test
Table 8-9. Maximum Meter Reading
COMPONENTS MILLIAMPERES
TSM 0.5
ECM 1
Regulator 2
p0093x8x
Load
Tester
● Any reading that exceeds the “Meter reading” values
indicates excessive current draw. Check for bad radio, voltage regulator or a short in the interconnecting wiring. Alarms and customer accessories are also prime sus­pects. Isolate problem by disconnecting suspect compo­nents and observe change in meter reading.
Total Current Draw Test
See Figure 8-33. If the battery runs down during use, the cur­rent draw of the motorcycle components and accessories may exceed the output of the charging system. To check for this condition, place load tester induction pickup or current probe pickup over battery negative cable as shown below. Disconnect regulator from stator. Start engine and run at 3000 RPM.
With ignition and all continuously running lights and accesso­ries turned on (headlamp on high beam), read the total cur­rent draw. Compare this reading to the reading obtained in
Current and Voltage Output Test. The current output should
exceed current draw by 3.5 amps, minimum. If not, there may be too many accessories for the charging system to handle. Reconnect regulator when test is complete.
NOTE
Rider’s habits may require output test at lower RPM.
Figure 8-33. Check Current Draw: Ignition Switch ON
8-28 2003 Dyna Police: Electrical
Page 69
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p0095x8x
p0096x8x
Current and Voltage Output Test
1. Connect load tester negative and positive leads to bat­tery terminals and place load tester induction pickup over positive regulator cable as shown in Figure 8-34.
2. Run the engine at 3000 RPM and increase the load as required to obtain a constant 13.0 volts.
3. The current output should read 41-48 amperes. Make note of the measurement.
Voltage Output Test
See Figure 8-34. After removing the load, read the load tester voltage meter. Voltage to the battery must be less than 15 volts. If voltage is higher, regulator is not functioning properly or connections are loose or dirty.
CAUTION
Do not leave any load switch turned on for more than 20 seconds or overheating and tester damage are possible.
Load tester
Figure 8-35. Test for Grounded Stator
To Circuit
Breaker
(DC Output)
To voltage
regulator
p0094x8x
Figure 8-34. Current and Voltage Output Test
Figure 8-36. Check for Stator Resistance
Stator Check
1. To check for a grounded stator, turn off ignition and dis­connect the regulator from the stator.
2. See Figure 8-35. Connect an ohmmeter on the RX1 scale between primary cover bolt and either stator socket. Use Harness Connector Test Kit (HD-41404), red pin probes and patch cords. There should be no continu­ity (∞ ohms) across either test point. Any other reading indicates a grounded stator which must be replaced. See
8.14 CHARGING SYSTEM ALTERNATOR ROTOR/STA­TOR for stator replacement.
3. See Figure 8-36. Check the resistance using an ohmme­ter set on the RX1 scale. Resistance should be less than
0.5 ohms across the stator socket. If it is not, then the stator is damaged and must be replaced. See 8.14
CHARGING SYSTEM ALTERNATOR ROTOR/STATOR
for stator replacement.
2003 Dyna Police: Electrical 8-29
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AC Output Check
1. See Figure 8-37. To test AC output, disconnect the regu­lator and connect an AC voltmeter across both stator sockets. Run the engine at 2000 RPM. The AC output should read 19-26 VAC per 1000 RPM.
2. If the output is below specifications, charging problem could be a faulty rotor or stator. Replace the rotor or sta­tor. See 8.14 CHARGING SYSTEM ALTERNATOR
ROTOR/STATOR for rotor or stator replacement.
3. Check the output again. See 8.14 CHARGING SYSTEM
TESTING, Current and Voltage Output Test.
p0097x8x
Figure 8-37. Check AC Output
8-30 2003 Dyna Police: Electrical
Page 71
1. Fuel gauge
2. Gasket
3. Screw (5)
4. Pin terminal
5. Pin housing
6. Terminal pin
7. Terminal socket
8. Fuel gauge sending unit
9. Fuel sender gasket
1
2
3
4
p0112a8x
7
6
7
5
8
6
9
HOME

FUEL GAUGE 8.15

GENERAL

● The fuel gauge is mounted in a simulated left fuel tank
cap. Remove by gently pulling upward. Do not twist.
● The light bulb may be replaced without further disassem-
bly when the gauge has been removed. Remove the gauge as described below and pull straight up.
● If gauge is to be replaced, remove wires from back of
gauge.
● Sending unit is located beneath gauge and can be
removed from fuel tank by removing the five screws securing it to the tank.

REMOVAL

NOTE
The gauge wires are routed through a tube in the tank and are secured by a clamp at the bottom of the tank. Loosen clamp and be sure there is enough slack in the wires to be able to lift the gauge.
Gasoline is extremely flammable and highly explosive. Always stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near the work site. Inadequate safety precautions could result in death or serious injury.
1. See Figure 8-38. Pull up on gauge (1). Detach pin termi­nals (4) from pin housing (5).
2. Remove screws (3) on sending unit plate ONLY.
Be careful not to bend float arm while removing. A bent float arm will give inaccurate readings.
3. Carefully move gauge back and forth while lifting.
1WARNING1WARNING
CAUTION
Figure 8-38. Fuel Gauge

INSTALLATION

1. See Figure 8-38. Use new screws and install new send­ing unit making sure to use new gasket for proper seal­ing.
2. Install sending unit plate screws (3). Tighten screws to 18-22 in-lbs (2.0-2.5 Nm). Tighten and secure wire clamp at bottom of fuel tank.
3. Connect terminals (6, 7) from gauge to sending unit (8).
4. Connect pin terminals (4) to pin housing (5).
5. Position terminals between posts on bottom of gauge.
6. Install gauge by carefully moving gauge back and forth while pushing down at the same time.
2003 Dyna Police: Electrical 8-31
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NOTES
8-32 2003 Dyna Police: Electrical
Page 73
able Of Contents
T
SUBJECT PAGE NO.
FXDP Dyna Police Model
Main Wiring Diagram .............................................................................................. A-1
Lights, Instruments and Indicators .......................................................................... A-2
Ignition Circuit ....................................................................................................... A-3
Lighting Circuit (Sheet 1 of 2) ................................................................................. A-4
Lighting Circuit (Sheet 2 of 2) ................................................................................. A-5
Charging and Starting Circuit .................................................................................. A-6
Horn and Instruments (Sheet 1 of 2) ....................................................................... A-7
Horn and Instruments (Sheet 2of 2) ........................................................................ A-8
Police Equipment Circuit ......................................................................................... A-9
HOW-TO-USE THESE WIRING DIAGRAMS
The wiring diagrams identified with page numbers “A-1”, “A-2”, etc. are overall diagrams that include all electrical systems and their associated wiring and electrical connectors. Circuit specific diagrams for Starting, Charging, Ignition, etc. also have been added. The circuit specific diagrams show only the components and wiring in the specific system(s) listed in the page title. Once a problem has been isolated to a specific system or circuit, use the diagrams to simplify location of the problem.
NOTE
Harness part numbers may be included on some wiring diagrams. Use these numbers for reference purposes only. ALWAYS REFER TO THE PARTS CATALOG WHEN ORDER­ING WIRING HARNESSES.
APPENDIX
Page 74
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