— DYNA° MODELS 2016 HARLEY-DAVIDSON® SERVICE MANUAL ea)2016 Harley-Davidson Dyna Models Service ManualREADER COMMENTS ‘The Harley-Davidson Service Communications Department maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of this manual. Please comment on the completeness, accuracy, organization, usability, and readability of this manual ' ' t ' 1 1 1 1 1 1 Pl ist the page, item, and part number(s) of any errors you find in this manual Please tell us how we can improve this manual. Occupation: Nam Dealership: Street: Department: City: State: Zip: curlers 2016 Harley-Davidson Dyna Models Service Manual (99481-16) Please clip out and mail to: ‘Service Communications Department Harley-Davidson Motor Company P.0, Box 653 ‘Milwaukee, WI USA 53201 1 ' 1 t ' ' ' 1 1 1 1 1 1 t t 1 ' 1 ' 1 1 1 I I 1 1 ' ' t 1 1 1 1 1 1 Il ' ' t ' 'NOTESABOUT THIS MANUAL GENERAL SZGOUAc} ‘The rider's safety depends upon proper motorcycle service ‘and maintenance. If a procedure in this manual is not within your capabilities or you do not have the correct tools, have @ Harley-Davidson dealer perform the pro- cedure. Improper service or maintenance could result in doath or serious injury. (006276) ‘This service manual has been prepared with the following ‘purposes in ming: + To acquaint the user with the construction of the Harley- Davidson product and assist in the performance of basic maintenance and repair. + Tointroduce tne professional Harley-Davidson technician to the latest feld-tested and factory-approved major repair methods. We sincerely believe that this service manual wall make your association wih Harley-Davidson products more pleasant anc profitable HOW TO USE YOUR MANUAL. Refer to the table below for the content layout ofthis manual EEE Eeraees | [Maintenance Chassis [Engine Fuel Systern Drive ‘Transmission ‘Appendix A Wiring ‘Appendix B Reference Use the TABLE OF CONTENTS (which follows this FORE~ WORD) and the INDEX (atthe back of this manual) to quickly locate subjects. Chapters and topics in this manual are sequentially numbered for easy navigation For example, a crosselerence shown as 2.2 ‘SPECIFICATIONS refers to chapter 2 CHASSIS, heading 22 ‘SPECIFICATIONS. For quick and easy reference, all pages contain a chapter number followed by a page number. For example, page 3-5 refers to page 5 in Chapter 3. ‘A number of acronyms and abbreviations are used in this document. See the B.4 GLOSSARY for @ list of acronyms, abbreviations and definitions. PREPARATION FOR SERVICE [PART NUMBER. HD-48650 TOOL NAME DIGITAL TECHNICIAN I Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks neat ‘gasoline. Gasoline is extremely flammable and highly ‘explosive, which could result in death or serious injury. (000028) Good preparation is very Important for efficient service work Start each job with a clean work area. This wil allow the repair to proceed as smoothly as possible. It will also reduce the Incidence of misplaced tools and part. Clean a motorcycle that is excessively dirty before work starts ieaning wil occasionally uncover sources of trouble. Gather any tools, instruments and any parts needed forthe job before, Work begins. Interrupting a job ta locate tools or parts is a dis- fraction and causes needless delay. NOTES + To avoid unnecessary disassembly, carefully read all related service information before repair work begins. + In figure legends, the number which follows the name of «a part indicates the quantity necessary for one complete assembly. + When servicing @ vehicle equipped with the Harley: Davidson Smart Securly System (H-DSSS), frst disarm the system. Keep the fob close to the vehicle or use DIGITAL TECHNICIAN II (Part No. HD-48650) to disable the system. Activate the system after service is completed. SERVICE BULLETINS Inaddition tothe information presented inthis manual, Harley- Davidson Motor Company will periodically issue service but latins to Harley-Davidson dealers. Service bulletins cover interim engineering changes and supplementary information. Consult the service bulletins to keep your product knowledge current and complete. USE GENUINE REPLACEMENT PARTS. Worcs Harley-Davidson parts and accessories are designed for Harley-Davidson motorcycles. Using non-Harley-Davidson parts or accessories can adversely affect performance, stability or handling, which could result in death or serious injury. (000018) To achieve satisfactory and lasting repair, carefully follow the service manual instructions and use only genuine Harley- Davidson replacement parts. Behind the emblem bearing the. wards GENUINE HARLEY-DAVIDSON stand more than 100 years of design, research, manufacturing, testing and inspecting experience. Thisis your assurance thal the parts you are using will ft right, operate properly and last longer. FOREWORDWARNINGS AND CAUTIONS Statements in this manual precedad by the following words ‘are of special significance, WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious Injury. (001192) een CAUTION indicates a potontially hazardous situation which, if not avoided, may result in minor or moderate injury. (001399) NOTICE NOTICE indicates a potentially hazardous situation which, if not avoided, may result in property damage, (001400) NOTE Refers to important information. It is recommended that you take special notice of these items Proper service and repair are important for the safe, reliable ‘operation of all mechanical products, The serviee procedures recommended and described in this manual are effective ‘methods for performing service operations, ONG) Always wear proper eye protection when using hammers, arbor or hydraulic presses, gear pullers, spring com- pressors, slide hammers and similar tools. Flying parts ‘could result in death or serious injury. (00496b) ‘Some of these service operations require the use of tools specially designed for the purpose. These special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service methods, wich could damage the motorcycte or render it unsafe, are stated in this manual. However, remember that these warnings are not allinclusive. Inadequate safety precautions could result in death or serious injury Since Harley-Davidson could not possibly know, evaluate or advise the service trade ofall possible ways in which service might be performed, or of the possible hazardous con- ‘sequences of each method, we have not undertaken any such broad evaluation. Accordingly, anyone who uses 2 service Procedure or tool which is not recommended by Harley- Davidson must first thoroughly satisfy himself that neither his ror the operator's safety willbe jeopardized as a result. Failure to do so could result in death or serious injury Ml FOREWORD PRODUCT REFERENCES Pana Read and follow warnings and directions on all products, Failure to follow warnings and directions can result in death or serious injury. (004700) When reference is made in this manual to @ specific brand ‘name product, tool or instrument, an equivalent product. too! Or instrument may be substituted Special Tools All tools mentioned inthis manual th apart number beginning with “HD”, "J or "B" must be ordered through your iocal Harley Davidson dealer. Special tools may only be purchased, serviood ‘or warrantied through @ Harley-Davidson dealer. LOCTITE Sealing and Threadlocking Products ‘Some procedures in this manual cal forthe use of LOCTITE products. fyou have any questions regarding LOCTITE product. Usage or retailer)wholesaler locations, contact Loctite Carp. at www loctte.com, PRODUCT REGISTERED MARKS Apple, Alcantara S.pA., Allen, Amp Multiock, Bluetooth, Brembo, City Navigator, Delphi, Deutsch, Dunlop, Dynojet, Fluke, GE, Versilube, Garmin, Gunk, Hydroseal, Hylamar ‘Phone, iPod, Keviar, Lexan, Lociite, Lubriplate, Keps, K&N, ‘Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex; ‘Micholin, MPZ. Mulitiock, nano, NGK, Novus, Packard, Piel Permatex, Philips, Put, Pozidtiv, Road Tech, Robinair, $100 ‘Sems, SiriusXM, Snap-on, Teflon, Treadlocker, Toroa, Torco, TORK, Tufoil, Tyco, Ultratoreh, Velero, X-Acto, XM Satelite Radio, and zomo are among the trademarks of thelr respective H-D U.S.A., LLC TRADEMARK INFORMATION Bar & Shield, Boom!, Cross Bones, Cruise Drive, CVO, Digital Tech, Digital Technician, Digital Technician II, Dyna, Electra Glide, Evolution, Fat Bob, Fat Boy, Fory-Eight, Glaze, Gloss H-D, H-Dnet com, Harley, Harley-Dayidson, HD, Heritage Softly, ron 863, Low Rides, Night Rod, Nighister, Night Train, Profile, Reflox, Revolution, Road Glide, bad King, Road Tech, Rocker, Screamin’ Eagle, Seventy-Two, Softail, Sportster, Street Glide, Street Rod, Sun Ray, Sunwash, Super Glide, SuperLow, Supersmart, Switchback, SYN3, TechLink, TechLink |i, TourPak, Th Glide, Twin Can’88, Twin Cam 886, Twin Camm 96, Twin Cam 968, Twin Cary 103, Twin Gam 1036, Twin Gam 110, Twin Cam 1108, Twin-Cooled, Ultra Classic, V-Rod, RSC and Harley-Davidson Genune Motor Parts and Genuine Motor Accessories are among the trademarks of H-O U.S.A, Luc,CONTENTS ‘Since product Improvement is our continual goal, Harley~ = Davidson reserves the rightio change specifications, equipment All photographs, illustrations and procedures may not neces- or designs at any time wihout notice and without incurring sarily depiet the most current model or component, but are obligation, ‘based on the latest production information available a te time ‘of publication FOREWORD IiNOTES IV FOREWORDMAINTENANCE 1.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter a4 1.2 GENERAL Servicing a New Motorcyct. 13 Safe Operating Maintenance, 43 Disposal and Recycling 13 ‘Shop Practices. 13 Repair Notes. 43 Safety. 4-3 Removing Pars, 43 Cleaning... 43 Disassembly and Assembly 14 Checking Torques on Fasteners. 14 Magnetic Parts Trays. 14 Repair and Replacement Procedures, 14 Hardware and Threaded Parts rata Threadiocking Agents. 14 Wiring, Hoses and Lines. 44 Instruments and Gauges. it Bearings. 44 Bushings. 44 Gaskets. 1-4 Lip-Type Seals, 14 ‘O-Rings. 1-5 Gears. 15 Shafts. 45 Part Repiacement 15 Cleaning 45 Protecting Rubber Paris, . 15 Cleaning Process. 15 Fust or Corrosion Removal 15 Bearings. 15 Too! Safety 15 Air Tools. 15 Wrenches. 15 PliersiCuttersiPry Bars. 16 Hammers 1-6 Punches/Chisels. 16 Sorewdrivers. . 18 Ratchets and Handles... 16 Sockets. 16 Storage Units... 16 4.3 FUEL AND OIL FU a7 Gasoline Blends, 417 Engine Lubrication... 42 Winter Lubrication, 18 1.4 MAINTENANCE SCHEDULE General +9 1.5 ENGINE OIL AND FILTER ‘Check Engine Oil Levet 414 ‘Oil Level Cold Check... 444 Gil Level Hot Check, 44 ‘Changing Oil and Oil Filter. A446 1.6 AIR CLEANER AND EXHAUST SYSTEM Removal, All But HO108 ns sd $6 Installation, All But HO103, 117 Removal, HO103 117 Installation, HO103. IAB Check Exhaust System Leakage. 9418 Exhaust System Leakage. 448 1.7 TIRES AND WHEELS Tres. 149 Tite Replacement. sat AD Duniop. 4-20 Michelin. i 4-20 Wheel Bearings. 121 Wheel Spokes. 4-21 Identify Wheel Spoke Groups. 4-21 ‘Adjust Wheel Spokes. 421 1.8 PRIMARY CHAINCASE LUBRICANT General Change Primary Chaincase Lubricant 4-23 1.9 TRANSMISSION LUBRICANT Check Transmission Lubricant... 4-25 Change Transmission Lubricant, 4-25 1.10 CLUTCH ‘Adjustment. 427 1.11 DRIVE BELT AND SPROCKETS General a 4-29 Cleaning. ni 4-23 Inspection 4-28 Sprockets. 4-29 Drive Bett... 4-29 (Check Drive Belt Deflection : 4-30 Adjusting Belt Deflection. 4-31 4.12 THROTTLE CABLES Cable Inspection and Lubrication. 4-33 Cable Adjustment. 4-33 Operation. ei 4-33 Adjustment... 4-33 1.13 CABLE AND CHASSIS LUBRICATION General 4-35 Cables and Hand Levers. - 4-35 ify Stand. rae 4.35 1.14 BRAKES Fluid inspection. 4-36 Rear Pedal Height. 1-36 Inspect Brake Lines. 1-38 41.15 BRAKE PADS AND DISCS Inspection 1-38 Brake Pads. 4-38 Brake Disc: - 4-38 Brake Pad Replacement 1-39 Rear Brake Caliper. 139 Front Brake Caliper. 1.39 1.16 SPARK PLUGS Inspection 441 4.17 STEERING HEAD BEARINGS Adjustment. 4-42 Bearing Adjustment (Measurement). soot Bearing Adjustment (Fall-Away). 1-42 TABLE OF CONTENTSTABLE OF CONTENTS Lubrication. 4-43 4.18 BATTERY MAINTENANCE General 4-44 Cleaning and inspection, 1-45 Voltage Test... 4.45 Charging Battery, 4-45 Safety Precautions...cnnnn 85; Using a Battery Charger. 1-45 Disconnection and Removal 4-48 Storage 4-47 Installation and Connection, 1-47 1.19 ENGINE MOUNTS Inspection. 4-48 1.20 HEADLAMP ALIGNMENT Headiamp Alignment 4-49 Headiamp Adjustment: All BUT FLD and FXDL. 1-49 Headlamp Adjustment: FLD. ae 1-50 Headlamp Adjustment: FXOL 1-50 4.21 SUSPENSION ADJUSTMENTS Shock Absorber Preload Adjustment, 151 1.22 STORAGE General tea 1-52 Placing in Storage. 4-52 Removal from Storage. 1-52 1.23 TROUBLESHOOTING General 1-83 Engine 1-53 ‘Starter Motor Does Not Operate or Does Not Turn Engine Over. 4-53 Engine Turns Over But Does Not Start 1-53, Starts. Hard 4-83 Staris But Runs Iregularly or Misses. 4-53 Spark Plug Fouls Repeatedly. 1-53 Pre-gnition or Detonation (Knacks oF Pings) ....00.1-53 Overheating : 1-54 Valve Train Noise. 4.84 Excessive Vibration nant BA Check Engine Light lluminates During Operation... 1-54 Lubrication System... 1-54 il Does Not Return To Oil Pan, 1-54 Engine Uses Too Much Oi Or Smokes Excessively..1-54 Engine Leaks Oil From Cases, Pushrods, Hoses, Ete. Low Oi! Pressure. High Oil Pressure, Electrical System... Alternator Does Not Charge. ‘Alternator Charge Rate Is Below Normal Speedometer Operates Erratcally ‘Transmission, - Shifts Hare. Jumps Out Of Gear. Clutch Stips, Clutch Drags Or Does Not Release. ‘Clutch Chatters VI TABLE OF CONTENTS Hening 465 iregularives. 1-55 Brakes. 1-85 Brake Does Not Hold Normally 1-85 CHASSIS 2.4 FASTENER TORQUE VALUES Fastener Torque Values In this Chapter 24 2.2 SPECIFICATIONS Specifications fo er ‘Chassis Specifications 26 The Spectctions. 27 2.3 VEHICLE IDENTIFICATION NUMBER (VIN) Vehicle Wentication Number 29 2.4 FRONT WHEEL Removal 214 Disassembly 211 Cast Wheel : 21 Cast Wheel, Dual Brakes. 21 Laced Wheel meet Cleaning and Inspection 2.15 ASSEMBIY os 216 Cast Wheel 2:16 Laced Wheel 216 Installation 218 2.5 REAR WHEEL Removal 248 Disassembly 218 Clearing and Inspection 219 Assembly. 2-20 Installation cai 2-20 2.6 SEALED WHEEL BEARINGS Inspect 222 Removal 222 Installation, pee 2.7 WHEEL LACING Whee! Lacing: Angle Flange Hub. 2.26 Whee! Lacing: Straight Flange Hub, Single Hole Circle,..2-27 Whee! Lacing: Straight Flange Hub, Dual Hole Circle... 2-29, 2.8 CHECKING AND TRUING WHEELS General ne Checking Wheel RUNOUt nm : 231 Checking Radial Runout 231 Checking Lateral Runout ange Laced Wheel Rim Offset. ‘ 232 ‘True Laced Wheels. 235 ‘Adjust Radial Runout 235 ‘Adjust Lateral Runout, 2.35 2.9 VEHICLE ALIGNMENT Inspection 237TABLE OF CONTENTS 2.10 FRONT BRAKE MASTER CYLINDER General Removal and Disassembly, Cleaning and Inspection Assembly and Installation. 2.11 FRONT BRAKE CALIPER Removal Disassembly. Cleaning, Inspection and Reparr. Assembly Installation, 238 239 24 241 243 243 245 2.48 247 2.12 REAR BRAKE MASTER CYLINDER Removal Disassembiy Cleaning and Inspection Assembly. Installation 2.13 REAR BRAKE CALIPER Removal, Disassembiy. Cleaning, Inspection and Repair Assembly Installation, 2.14 BRAKE LINES Front Master Gylinder to Front Caliper Line Assembly. Removal Instalation ‘ABS Module to Front Manifold Brake Lines. Removal Instalation. Rear Master Cylinder to ABS Module. Removal. Installation. ABS Module to Rear Brake Caliper. Removal Installation. 2.15 ABS MODULE (eHcuy General... Electro Hydraulic Control Unit (EHCU), or “ Instaliation 2.16 BLEEDING BRAKES General Procedure... 247 TIRES General Remove. Clean, Inspect and Repair Installation, Tube Type Tires. Tubeless Ties. Check Tire Runout... Lateral Runout Radial Runout 249 251 52 258 2-58 2-58 2-58 2-58 2.60 61 261 son 2-61 263 2-63 263 2.65 265 2.65 2.87 2-68 268 270 2-70 2-70 271 271 27 “272 272 272 Balance Wheel. 212 Static vs Dynamic. 272 Weights 2.73 2.18 FRONT FORK (Check For Oil Leak. 274 Fork Oil Seals. 274 Check Oil Leak 2-74 Removal. 274 Disassembly: All But FLD eft Side. 274 Disassembly: Cartridge Ferk (FLD, Left $102) ores 277 Cleaning and inspection an... 2-78 Assembly: All Bul FLO Left Side. 2.80 ‘Assembly: Cartridge Fork ‘FLD, Left Side)... 281 Installation, 2-83 2.19 STEERING HEAD Removal: All But FLD. 2.85 Removal: FLD. sn BB5 {inspection 7 2-86 Disassembly. 2-86 Sleering Head Beanng Race Removal 2-86 ‘Assembly. 7 2-86 Installation: All but FLO. 2-86 Installation: FLO. 287 2.20 BELT GUARD AND DEBRIS DEFLECTOR Belt Guard Removal 2-89 Belt Guard Installation. 2.89 Debris Deflector Removal 2-89 Debris Deflector Installation, 2.89, 2.21 THROTTLE CONTROL RemovaliDisassembly 201 Cleaning and inspection. 201 ‘Assembiy/instalation, 291 Throttle Cable Routing 2-92 2.22 REAR SHOCK ABSORBERS General 2.98 Removal 2-93 Inspection. 2.93 Installation 2.93, 2.23 REAR FORK Removal 294 Disassembly. i 2.94 Cleaning ana Inspection 2.95 ‘Assembly. 2-95 Installation 295 2.24 CLUTCH CONTROL Removal... 1 2-96 Installation, - 2.96 2.25 HANDLEBAR: FLD Removal... 297 Installation 297 Left Hand Grp. nd 9B Removal. 2-98 ‘TABLE OF CONTENTS VilTABLE OF CONTENTS Installation, 2.26 HANDLEBAR: FXDB, FXDBC, FXDBP, FXDF AND FXDWG 298 Removal 2.99 FXDB, FXDBC, FXDBP. 229 FXOF and FKDWG. 2-400 Installation 2401 2.27 HANDLEBAR: FXDL Removal. 2-404 Installation, x = 2-104 Handlebar and Riser Adjustment. 2408 2.28 FRONT FENDER Removal 2407 Installation 2407 2.29 REAR FENDER General 2-408 Removal "2-408 Tail Lamp/Tum Signal Harness Routing 2-408 Installation 2-408 FXDL. 2411 Removal 21M Instalation 2411 FXDB, FXDBC, FXDBP, 2411 Removal. 2411 Installation. AN FXOWG. 2112 Removal 2412 Sissy Bar. 2113 Instaltation 2413 FLD. 2144 Removal 2414 Disassembly. 2414 Assembly. 2414 Installation, 2418 FXOF. Removal 2415; Installation 2415 2.30 SEAT Removal. vn eT ene BANT Seat and Seat Strap: All But FADWG. BAT Seat and Seat Strap: FXDWG. 2N7 Installation, ae B18 ‘Seat and Seat Strap: All But FXDWG. 2118 Seat and Seat Strap: FKOWG. P18 ‘Lumbar Pad: FDL. 2119 Removal 2419 Installation 2419 2.31 FOOTBOARDS AND FOOTRESTS Rider Footboards 2-120 Removal. 2-420 Disassembly. 2-120 Assembly. 2-120 Installation. a 2120 Rider Footrests: Mid Controls. 2-124 Removal 2424 Vill TABLE OF CONTENTS: Installation... 2 Rider Footrests: Forward Controls, 2-122 Removal. 2422 Installation. = 24122 Passenger Footrests: All But FXDB. 2122 Removal. 2422 Installation 2122 2.32 HEADLAMP NACELLE: FLD Upper and Lower Nacelie, 2-124 Removal. (2-124 Installation 2126 2.33 WINDSHIELD: FLD Windshield 2-128 Removal... 2125 Installation, 2125 Windshield Window. 2425 Removal. 2425 Installation 2427 2.34 SADDLEBAGS: FLD Saddlebag, 2428 Removal... 2-128 Installation, 2128 Disassembly. 2128 ‘Assembly. 2-129 Saddlebag Lid 2430 Seal 2-130 Disassembly. 2-431 Assembly. 24131 2.35 JIFFY STAND leaning, 2433 sitfy Stand Sensor: HDI Models. 2435 Removal 2135 Installation, 2435 2.36 FORK LOCK Removal 2437 Installation, 2437 2.37 ENGINE MOUNTS: Removal 24139 Front Isolator 2.439 Rear Isolator 2-439 Installation, 2-439 Front Isolator, 2-438 Rear Isolator. 2-139 2.38 SAREE GUARD: INDIA MODELS Replacement. 2441 Removal 2141 Installation 2441 2.39 MEDALLIONS, BADGES AND TANK EMBLEMS Removal, Installation. 2442 2442ENGINE 3.1 FASTENER TORQUE VALUES Fastener Torque Valves in this Chapter 34 3.2 SPECIFICATIONS Specifications. 38 3.3 SERVICE WEAR LIMITS. General 36 3.4 ENGINE OIL FLOW Oil Fees. 37 Top End. 37 Bottom End 39 il Return, ott 3.5 OIL PUMP OPERATION General 342 Operation, 342 3.6 BREATHER OPERATION General. oa 314 3.7 OIL PRESSURE il Pressure Indicator Lamp. 3415 Checking Oil Pressure. i AS 3.8 TROUBLESHOOTING Diagnosing Valve Train Noise. 347 Compression Test. 317 Cylinder Leakdown Test 348 Biagnosing Smoking Engine or High Oil Consumption... 3-18 (Check Before Cylinder Head Removal: 318 Check After Cylinder Head Removal 38 3.9 HOW TO USE THIS SECTION “Top End Repair. 349 Bottom End Repair 349 ‘Typical Symptoms. 3418 3.10 TOP END SERVICE Engine in Chassis, 3-20 Engine Removed from Chassis. 321 3.11 CAM COMPARTMENT SERVICE Replace Camshaf, Engine Removed From Chassis. 3.12 STRIPPING MOTORCYCLE FOR SERVICE Procedure. 324 ‘Cam Compartment Service Oniy. 3.24 Complete Top End Service... 3.24 3.13 ASSEMBLING MOTORCYCLE AFTER SERVICE Procedure 325 TABLE OF CONTENTS 3.25 325 3.14 REMOVING ENGINE FROM CHASSIS ‘Aller Complete Top End Service, ‘After Cam Compartment Service Only. Procedure = 326 3.15 INSTALLING ENGINE IN CHASSIS Procedure 327 3.16 TOP END OVERHAUL: DISASSEMBLY General 3-29 Rocker Covers 329 Rocker Arm Support Pate. 325 Pushrods, Lifters and Covers eB Cylinder Head. 331 Cylinder 332 Piston... i im 393 3.17 BREATHER ASSEMBLY Disassembly 335 Cleaning and inspection 3-35 Assembly, 3-35 3.18 ROCKER ARM SUPPORT PLATE Disassembly. 3.36 Cleaning, Inspection and Repair. 3-96 Inspection. 3-36 Rocker Shaft Fit 3-38 Rocker Arm Shaft to Bushing, 337 Ropiee Rar fer Bushings» nT ‘Assombly. 3-38 3.19 PUSHRODS, LIFTERS AND COVERS Disassembly. 3.39 Cleaning and General Inspection 339 Inspect Litters. 3.40 Assemble. 3-40 3.20 CYLINDER HEAD Determining Service 342 Disassembly. 3-42 Cleaning, 343, Inspection 383 Cylinder Head, 3-43 Valve Guides. 344 Valves, 3.44 Valve Springs. Baa Tapered Keepers 344 Valve Seats. ce 344 Valve Guide Replacement. 344 Removal 344 Installation. 3.45 Valve and Seat Refacing. 3.48 Assombly. 3-60 3.21 CYLINDER Cleaning 362 Inspection 3-52 Deglazing Cylinder... 358 Boring and Honing Cylinder. 3.54 ‘TABLE OF CONTENTS 1XTABLE OF CONTENTS 3.22 PISTON Disassembly 3-56 Piston Rings... 3-56 Cleaning, 3-56 Inspection, 3.56 Assembly. a 358 Checking Piston Ring Gap. 3-58 Installing Piston Rings. 358 3.23 TOP END OVERHAUL: ASSEMBLY General 3-60 Piston. 3-60 Cylinder... pn 381 Cylinder Head 3.63 Pushrods, Lifters and Covers. =n 3-66 Rooker Arm Suppor Plate. 347 Breather and Rocker Gover. 3.68 3.24 CAM COMPARTMENT AND COMPONENTS ‘Cam Support Plate and Cover Removal 370 Prepare Engine. 370 Cam Chain and Sprockets Removal. sen 1 Cam Support Plate Removal a7 Cam Support Piate Cleaning and Inspection. 372 ll Pressure Relief Valve. ne BTR ‘Cam Support Plate. . 372 Camshafts 372 Removal. 372 Installation. 3-73 Oil Pressure Relief Valve, eT Removal 374 Inspection... 375 Instaliation. 3-75 ‘Cam Needle Bearings 375 Removal. mu Installation. 377 ‘Cam Support Plate and Cover Installation. 378 3.25 OIL PUMP. Removal 383 Cleaning and Inspection. 3-83 instalation (384 3.26 CRANKCASE DISASSEMBLY AND REPAIR Crankcase Disassembly 3-85 Cleaning and inspection. 3-85 Right Crankcase Half 3-86 Main Bearing Removal 3.86 Main Bearing Installation. . ori 3-86 Piston Jets Removal. 387 Piston Jets Installation. 3-87 Left Grankease Half. 3.87 Main Bearing Removal 387 Main Bearing Installation, : 388 ‘Sprocket Shaft Bearing Inner Race. 3-89 Removal. . 3-89 Instaltation, Cylinder Studs, Removal X TABLE OF CONTENTS. ‘Installation, 392 Pipe Plug and Oil Fittings. . vn WD Removal 3.92 Installation, 3.82 3.27 FLYWHEEL AND CONNECTING RODS ‘Symptoms. on 93 Overview. 3.93 No Oil Pressure. 3.83 Vibration... 3.93 Inspection. . 3-93 Measuring Crankshaft Runout : 3-93 Crankshaft Installed 3.93 Crankshaft Removed. 7 3.94 3.28 CRANKCASE ASSEMBLY Crankcase Assembly, 3.95 3.29 OIL PAN Removal 3.97 Installation... : 3.97 FUEL SYSTEM 4.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapt... 44 4.2 SPECIFICATIONS: FUEL SYSTEM ‘Specifications. ee 4.3 AIR CLEANER ASSEMBLY Removal, All But HO103. Installation, All But HO103, Removal, HO103, Installation, HO103. Backplate Assembly: HDI Modals 4.4 FUEL TANK General Removal faning and Inspection Installation, Vapor Valve 4,5 THROTTLE POSITION SENSOR (TPS) General... sn AD Removal 412 Installation, ob 4.6 INTAKE AIR TEMPERATURE SENSOR (aT) General nn a . AS Removal 413 Installation, 413 4.7 ENGINE TEMPERATURE SENSOR REN General oases Ald Removal 414 Installation, vn ABTABLE OF CONTENTS 4.8 INDUCTION MODULE Removal Installation, 4.9 IDLE AIR CONTROL. (isc) General Removal, Installation, Ate 417 ANB 418 A18 4.10 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) General Removal Installation, 4.11 OXYGEN SENSOR General Removal Installation 4.12 FUEL INJECTORS General. Removal Installation, 4.13 FUEL PUMP. General Removal Disassembly and Assembly Fue! Fitter. Regulator. Inlet Sock. Fuol Pump. Installation, 4.14 FUEL PRESSURE TEST General Testing 4.15 EXHAUST SYSTEM Removal: FXDB, FXDBC and FXDBP. Disassembly: FXDB, FXOBC and FXDBP. ‘Assembly: FXDB, FXDBC and FXDBP. Installation: FXDB, FXOBC and FXDBP. Removal: FXDF and FXDWG. Installation: FXDF and FXDWG. Removal: FLD... Installation: FLD. Removal: FXDL. Installation: FXDL.... 4.16 INTAKE LEAK TEST General Leak Tester. Paris List... ‘Assemble Tester Adjust Taster... Procedure. 4-20 4-20 4-20 At 421 421 423 423 4-25 4.25 425 428 4.27 427 432 433 434 8-35 438 4.39 44% at 4-43 444 Add aad aad 44 4.17 EVAPORATIVE EMISSIONS CONTROL General (Charcoal Canister. Removal Installation, DRIVE 5.1 FASTENER TORQUE VALUES Fastener Torque Values inthis Chapter. 5.2 SPECIFICATIONS: DRIVE Specifications, 5.3 PRIMARY CHAINCASE COVER General Removal. Installation, 5.4 DRIVE COMPONENTS Removal Installation, 5.5 PRIMARY CHAINCASE HOUSING Removal Inspection... Mainshaft Bearing and Seal Removal. Installation, Mainshaft Bearing Inner Race... Removal Installation. Shifter Shaft Bushing Installation a 5.6 CLUTCH Removal and Installation. ‘Clutch Pack Only Partial Disassembly... Cleaning And Inspection Assembly... Clutch Pack and Bearing, Complete Disassembi. Assembly, 5.7 TRANSMISSION SPROCKET Removal. Cleaning and Inspection, Installation, 5.8 DRIVE BELT Removal Installation, TRANSMISSION 6.1 FASTENER TORQUE VALUES Fastener Torque Values inthis Chapter. ~AAB 448 448 4-48 Bt 53 53 53 5-10 5-10 510 5-10 540 Bn 5A 511 512 512 544 514 544 514 515 516 516 57 518 518 519 521 ‘521 64 TABLE OF CONTENTS XITABLE OF CONTENTS 6.2 SPECIFICATIONS: TRANSMISSION Specifications Service Wear Limits. 6.3 TRANSMISSION Power Flow. Neutral First Gear Second Gear. Third Gear. Fourth Gear. Fifth Gear. Sixth Gear, 6.4 SHIFTER LINKAGE Shifter Rod Adjustment ' Forward Control Shifter Adjustment ‘Mid-Contro! Shifter Adjusiment. 6.5 CLUTCH RELEASE COVER Removal and Disassembly Cleaning and inspection ‘Assembly and Installation 6.6 TRANSMISSION ASSEMBLY Removal Disassembly, Shifter Carw/Shitter Forks. Mainshatt. Countershatt. Removing Bearing Housing Bearings, Cleaning and Inspection. Assembly. Instaling Bearing Housing Bearings. Countershatt Mainshat Shifter CamiShitter Forks. Installation, 6.7 MAIN DRIVE GEAR AND BEARING Removal. Cleaning and inspection, Needle Bearing Replacement Installation, Instaling Main Drive Gear Bearing, Installing Main Drive Gear. Installing Main Drive Gear Large Seal 6.8 TRANSMISSION CASE Removal... Instalation Disassembly. Shifter Arm Assembly, Cleaning and Inspection... Assembly. Countershaft Needle Bearing Replacement, Shifter Paw Lover Assembly. Xil TABLE OF CONTENTS: 62 62 64 6-4 es Bd 4 64 64 64 66 66 87 87 68 cy 6-10 610 12 6-14 615 6-16 B16 6-16 6-16 617 17 619 6-22 8-23 6-24 6:25 625 6-26 626 629 6-29 8-30 6-30 630 631 631 631 ELECTRICAL 7.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter. 7.2 SPECIFICATIONS: ELECTRICAL ‘Specifications. 7.3 ELECTRICAL CADDY Removal Installation, ™ 74 16 77 7.4ELECTRONIC CONTROL MODULE (ECM) General Replacement. Removal. Installation 7.5 BODY CONTROL MODULE (BCM) General Removal Installation, 7.6 SECURITY SIREN Removal Installation, 7.7 SPARK PLUG CABLES Inspect Spark Plug Cables. Removal Installation = 7.8 FUSES General Replacement. 7.9 IGNITION SWITCH Removal ‘ Al but FXOL. FXOL, Installation All but FXOL.... FXOL, 7.10 BATTERY TRAY AND BATTERY CABLES Battery Tray. Removal Installation Battory Cables, Routing 7.11 STARTER General Removal Drive Assembly. Disassembly Inspection, Assembly. 78 78 78 78 19 79 7-40 1-44 744 745 716 748 718 7 tl al 748 7-18 720 7-20 7-20 720 724 721Solenoid asa pat Remove Cover and Plunger 724 Short Post Contact: Starter 722 Long Post Contact: Battery Positive 722 Install Plunger and Cover. 7.23 Installation 723 7.12 HEADLAMP General 7-24 Bulb Removal All But FLD 724 Single Bulb Headlamp 7-24 Dual Bulb Headlam 7-25 Bulb installation: All But FLD. 7.26 Headlamp Assembly. All Bul FLD and FXOL. 728 Removal 7:28 Installation 7.25 Headlamp Assembly: FXDL. 7-26 Removal 7-26 Installation 7-26 Heaclamp Visor: FXOL. r27 Removal 727 Installation 7-27 Headlamp: FLD. 728 Removal 7-28 Bulb Replacement 7-29 installation 7-30 7.43 TAIL LAMP General 731 Tal Lamp Bulb Replacement: FLD and FXDL. 731 Base Replacement: FLO and FXDL 731 Base Replacement: FXOWGIHDI and Canada, 733 Tail Lamp Replacement, FXOF. 7-34 Tall Lamp Removal 7-34 Tall Lamp instalation... 7-34 License Plate Lamp Replacement 7-34 7.14 TURN SIGNALS Turn Signal Bulb Replacement: Bullet Sie. 7-36 Front Lamp Housing Replacement: All But FLD. 7-36 Rear Lamp Housing Replacement: All But FLO. 7-38 Front Turn Signal Lamps: FLD. 7-40 Removal 7-40 instalation 740 Rear Tum Signal Lamps and Bracket Tat Removal Tat Installation. Tat Rear Tum Signal Reflestorsolaor Repair FLD... 7-44 Removal. 784 instalation Tat 7.15 CRANK POSITION SENSOR (CKP) General 7-43 Removal 743 Installation. 743 7.16 AUTOMATIC COMPRESSION RELEASE (ACR) General 7-44 Removal. 7-44 installation. 744 TABLE OF CONTENTS: 7.17 VOLTAGE REGULATOR Removal 7-46 Installation 7-46 7.18 ALTERNATOR Removal T-4T ‘leaning and Inspection, 7-47 Installation. 787 7.19 FUEL GAUGE General 7-49 Removal 749 7.20 FUEL GAUGE SENDER Removal 7-50 Installation 751 7.21 INSTRUMENTS: FXDF AND FLD ‘Speedometer. 753 Removal... 7-53 installation 7-53 7.22 INSTRUMENTS: FXDB, FXDBC, FXDBP AND FXDWG Removal... I-54 Installation, 7.54 7.23 INSTRUMENTS: FXDL Removal 7-56 Instaliation. TB 7.24 VEHICLE SPEED SENSOR (VSS) General 787 Removal soe TBT Installation, 757 7.25 WHEEL SPEED SENSORS Front Wheel Speed Sensor (WSS). 7-58 Removal. " TSB Instalation 7-58 Rear Wheel Speed Senscr (WSS). 758 Removal 7-59 Installation 7-80 7.26 INDICATOR LAMPS Removal sn TBD FLO, 7-62 FXDB, FXDBC, FXDBP, FXDWG and FADF...n..7-82 Installation. 7-63 FLD. 7-83 FXDB, FXDBC, FXDBP, FXDWG and FXDF.......7-63, 7.27 NEUTRAL SWITCH General 784 Removal 7-84 Installation... 7-64 7.28 OIL PRESSURE SWITCH General 7-65 ‘TABLE OF CONTENTS XiTABLE OF CONTENTS Removal 785 Installation, 785 7.29 REAR STOPLAMP SWITCH General i 7-66 Removal 7-66 Installation, 7-66 7.30 HORN Inspection. 760 Replacement: All But FXDL. 787 Replacement: FXDL. 7-88 7.31 ACTIVE EXHAUST: HDI General 7-69 Removal 7-69 Repair. 7-69 Installation 7-69 7.32 MAIN WIRING HARNESS General a Removal : 744 Installation 773 7.33 HANDLEBAR CONTROL MODULES General 7 Repair Procedures. i 707 7.34 LEFT HANDLEBAR CONTROL MODULE Removal 778 ‘Clutch Switch Replacement, 778 Installation, . 778 7.35 RIGHT HANDLEBAR CONTROL MODULE Removal 7-80 Front Brake Switch Replacement Tat Installation, 7 cod BA 7.36 H-DSSS MAINTENANCE Fob Battery 7-83 Battery Replacement Schedule. 7-83 Battery Replacement. 7-83 ‘Smart Siren (If installed), 7.83 Battery Replacement Schedule. aT B3 Battery Replacement. 7-83 7.37 PERSONAL IDENTIFICATION NUMBER (PIN) General 784 XIV TABLE OF CONTENTS Changing The PIN. 7-84 Modifying an Existing PIN.. 7-84 7.38 H-DSSS ACTUATION Sidecar Configuration. 7-86 Activation 7-88 Fob Assignment 7-86 APPENDIX A WIRING A.1 CONNECTORS Connector Locations. Ad Function/Location, A Place and Color. AA Connector Number. Ad Repair Instructions A A.2 WIRING DIAGRAMS Wiring Diagram information Ad Wire Color Codes. Ad Wiring Diagram Symbols. A 2016 Dyna Wiring Diagrams. AG APPENDIX B REFERENCE B.1 LENGTH CONVERSION Conversion Table. Ba B.2 FLUID CONVERSION United States System. B2 Metric System. B2 British Imperial System. B2 B.3 TORQUE CONVERSION United States System. BS Metric System. B3 B.4 GLOSSARY ‘Acronyms and Abbreviations, Ba REFERENCE MATERIAL TOOLS TORQUE VALUES. INDEX...‘SUBJECT PAGE NO. 1.1 FASTENER TORQUE VALUES. 1.2 GENERAL. 1.3 FUEL AND OIL... 4.4 MAINTENANCE SCHEDULE. 1.5 ENGINE OIL AND FILTER... 1.6 AIR CLEANER AND EXHAUST SYSTEM. 1.7 TIRES AND WHEEL: 4.8 PRIMARY CHAINCASE LUBRICANT. 1.9 TRANSMISSION LUBRICANT. 4.10 CLUTCH... 1.11 DRIVE BELT AND SPROCKETS... 4.12 THROTTLE CABLES. 1.13 CABLE AND CHASSIS LUBRICATION, 1.14 BRAKES., " 1.15 BRAKE PADS AND DISCS. 1.16 SPARK PLUGS. 4.17 STEERING HEAD BEARINGS. 4.18 BATTERY MAINTENANCE... 4.19 ENGINE MOUNTS... 4.20 HEADLAMP ALIGNMENT. 4.21 SUSPENSION ADJUSTMENTS. . 1-48 151 1-52 1-53NOTESFASTENER TORQUE VALUES 41.4 FASTENER TORQUE VALUES IN THIS CHAPTER The table below ist torque valves forall asteners presented in this chapter RES LE Ae SS NOTES ‘ir cleaner cover bracket screw 40.60indbs | 45.58'Nm | 1.6 AIR CLEANER AND EXHAUST SYSTEM, instalation, A) But HO103 Aircleaner cover screw 3660 indbs 4 78BNm 16 AIR CLEANER AND EXHAUST, SYSTEM, installation, All But HO TO3/Apply LOCTITE 243 MEDIUM STRENGTH THREAD- LOCKER AND SEALANT (blue), ‘ir leaner cover screw 3660 indbs SYSTEM, instalation, HOTO3/Appl a drop of |LOCTITE 243 MEDIUM STRENGTH THREAD- | LOCKER AND SEALANT (ue) (fe adjusor 120-144 indbs | 136-163Nm 1.11 DRIVE BELT AND SPROCKETS, Adjusting | Belt Deflecton/Tighten afr axles tightened “fae nt, rear 95106 Ribs 1288-1424 Nm| 1.11 DRIVE BELT AND SPROCKETS, Adjusting | Belt Defecon | Battery terminal screw 60-70 in-ibs 687.9Nm 1.18 BATTERY MAINTENANCE. installation and | Connection Battery terminal sorow ~) 80-70indbs 6B7.9Nm 1.18 BATTERY MAINTENANCE. instalation and Connection | Brake line clamp screw: FXDL ("45-65 indbs —5.1-7.3Nm __ 1.17 STEERING HEAD BEARINGS, Adjustment [Brake maniois fastener 3648 indbs-40-54Nm _ 1.17 STEERING HEAD BEARINGS, Adjustment | Brake pad pin/bridge bolt, front caliper 15-16 ft-lbs. 20.3-22.6Nm 1.15 BRAKE PADS AND DISCS, Brake Pad Replacement Caliper, front, mounting bolt 28-38 ftlbs | 38.0-51.5Nm 1.15 BRAKE PADS AND DISCS, Brake Pad placement [Cite aster ere incbs | 8413.6Nm 1.10 CLUTCH, Adjustment | Clutch cable adjustment jamnut 120 in-Ibs 13.6 Nm 1.10 CLUTCH, Adjustment 7 [eave catia aera ates | EP |Chtch inspection cover scxews @4-108 ntbs | 915-12.2Nm 118 PRINARY CHAINCASE LUBRICANT, Change _Primary Chaincase Lubrican\/Torque sequence jf (Clutch inspection cover screws 4708 in-tbs | 9.5-122Nm | 110 CLUTCH, Adjustment ‘Cover insert screw 27-32 inbs | 31-3.6Nm 1.6 AIR CLEANER AND EXHAUST | ‘SYSTEM, Installation, HO103, Engine oil drain plug {#21 felbs | 19.0.285Nm | 1.5 ENGINE OIL AND FILTER, Changing Oil and Oil Fitter indbs | 2-6.8Nm 1.6 AIR CLEANER AND EXHAUST ‘SYSTEM, Installation, HO103/Apply LOCTITE 243 | MEDIUM STRENGTH THREADLOCKER AND Filter element screw 55- SEALANT (blue) Fork clamp pinch bolts: lower [3036 ibs | 407-475Nm 1.17 STEERING HEAD BEARINGS, Adjustment | Fork clamp stem nut 70-80 hibs | 95-108.5 Nv 7.17 STEERING HEAD BEARINGS, Adjustment | Front caliper mounting bolt 28-38 ribs 380-51.5\Nm 1.15 BRAKE PADS AND DISCS, Brake Pad | Replacement Headlamp clamp nut; FXDL 120-240 in-lbs | 14-27Nm 1.20 HEADLAMP ALIGNMENT, Headlamp | | adjustment: FXDL Headlamp horizontal adjusting bolt 25-30 ftibs | 339-407 Nm | 1.20 HEADLAMP ALIGNMENT, Headlamp “Adjustment: Al BUT FLD and FXDL 2016 Dyna Service: Maintenance 1-1Headlamp vertical adjusting nut 25.30 ftbs 389-40,7 Nm 1.20 HEADLAMP ALIGNMENT, Headlamp | Adjustment: All BUT FLD an FXDL Master cylinder reservoir cover screws:| 6-8 inbs. 0.7-09Nm (1.15 BRA font cover ‘Master cylinder reservoir cover screws:| 6-8 in-lbs 0.7-09Nm |1.15 BRAKE PADS AND DISCS, Brake Pad rear cover, including ABS ‘Repl Nacelle bolts, upper 84-120 indbs | 9.5-13.5Nm _|1.17 STEERING HEAD BEARINGS, Adjustment Pad pin, rear caliper 80-120 indbs | 9.0-13.5Nm 1.15 BRAKE PADS AND DISCS, Brake Pad pas =i Replacement ‘Primary chaincase drain plug 14-21 fs | 190-28.5Nm [1.8 PRIMARY CHAINCASE LUBRICANT, Change Primary Chaincase Lubricant | Rear caliper fasteners 16-20 felbs | 21.7-27.1Nm 1.15 BRAKE PADS AND DISCS, Brake Pad Replacement |Spark plug 12-18 fis | 16.3-24.4.Nm |1-16 SPARK PLUGS, Inspection ‘Spoke nippie | SS inbs 62Nm 1.7 TIRES AND WHEELS, Wheel Spokes | Switch housing screw 45in-ibs | 4.0-5.1Nm 1.12 THROTTLE GAELES, Cable Inspection and | ‘Transmission drain plug Transmission f ‘Transmission filler plugidipstick 4-2 2016 Dyna Service: Maintenance plugidinstick | Lubrication 28.5 Nim | 19 TRANSMISSION LUBRICANT, Ghange Transmission Lutvicat bs | 1k 25-75 intbs | 28-8.5Nm |1.9 TRANSMISSION LUBRICANT, Gheck Trans- [mission Lubricant 25-75 nibs | 2.8-8.5Nm (1.9 TRANSMISSION LUBRICANT. Change [Transmission LubricantGENERAL SERVICING A NEW MOTORCYCLE PcG) Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a) Perform necessary set-up tasks before customer delivery. See ‘applicable model year predelivery and set-up instructions, The performance of new motorcycle intial service is required to keep warranty in force and to verity proper emissions sys- tems operation. See 1.4 MAINTENANCE SCHEDULE. SAFE OPERATING MAINTENANCE NOTES Do not attempt to tighten engine head bolts or engine damage may result, During the initial breakin period, use only GENUINE HARLEY-DAVIDSON HD 360 MOTORCYCLE OlL 20WS50. Failure to use the recommended oll results in Improper break-in ofthe engine cylinders and piston rings Inspect motorcycle regularly for more maintenance needs, Routinely check components between regular maintenance intervals. Always inspect motorcycle after periods of storage before riding Cheek: 1. Tires for correct pressure, excessive wear or any signs of tire damage. Drive belt tension and condition Brakes, steering and throttle for responsiveness. Brake fuid level and condition. Hydraulic ines an! fitings for leaks (Check brake pads and discs for wear. Cables for fraying, erimping and trae operation Engine oll and transmission fluid levels, Headlamp, auxiianyffog lamp, tail lamp, stop lamp, horn and turn signal operation, DISPOSAL AND RECYCLING Help protect our environment! Many communities maintain facilities for recycling used fluids, plastics and metals. Dispose Of or recycle used oll, lubricants, fuel, coolant, brake Muid and batteries in accordance with local regulations. Many Harley- Davidson parts and accessories are made of plastics and ‘metals which can also be recycled. SHOP PRACTICES Repair Notes General maintenance practices are given inthis section, NOTES + Repair = Disassembly/Assembly. + Replacement = Substitute a new part for existing com- ‘ponent. [Al special tools and torque values are noted al the point of Al required parts or materials can be foundin the parts catalog. Safety ‘Safety is always the most important consideration when per forming any job. + Aways have a complete understanding ofthe task + Use common sense. + Use the proper tots, + Protect yourself and bystanders with approved eye protec- ton ‘Do not just do the jo, do the job safety Removing Parts ‘Always consider the weight of a part when iting. Uso a hotst Whenever necessary. Do not it heavy parts by hand, If host and adjustable iting beam or sing are needed to remave some parts, verty that + The lengths of matte chains or cables from the hoist to the part are equal and parallel + Slings, chains and cables are positioned directly over the center ofthe part + No obstructions interfere with the iting operation, + Parts are not left suspended. EG cd Be sure to check capacity rating and condition of hoists, slings, chains and cables before use. Exceeding capacity ratings or using lifting devices that are in poor condition, can lead to an accident, which could result in death or serious injury. (00466c) ‘Always use blocking or proper stands to support the par that, has been hoisted. a part cannot be removed, very that all bolts and attaching hardware have been removed. Verify that no parts are in the way of the part being removed, When removing hoses, wiring or tubes, always tag each part to venty proper installation, Cleaning ‘Always clean around lines or cavers before they are removed. Pug, tape oF cap holes and openings to keep out di, dust and debris. Clean and inspect all parts as they are removed. Verity thatall holes and passages are clean and open. After cleaning, ‘cover ll parts with clean lint-free cloth, paper or other material Verity that the partis clean when installed, “Thoroughly clean all parts tobe reused before assembly. Clean parts promote better component operation and longer life Seals, fillers and covers used in this vehicle keep out 2016 Dyna Service: Maintenance 1-3‘extraneous dit and dust, Keep these items in good condition to guarantee satislactory operation, ‘When instructed to clean fastener threads or threaded holes, always: + Clean allthreadlocking material from fastener threads and threaded holes + Use a wire brush to clean fastener threads. + Use a thread chaser or olher suitable tool to clean threaded holes + Use Put cleaner or equivalent to remove all traces of cil and contaminants from threads. + Clear all threaded holes with low pressure compressed Always verify cleanliness of blind holes before assembly. Tightening a sorew with ditt, water or oil in the hole can cause castings to crack or break. Disassembly and Assembly Always assemble or disassemble one part at a time, Do not work on two assemblies simultaneously. Make all necessary adjustments. Inspect your work when finished to verify that everything is done (Operate the vehicle to perform any final check or adjustments, Hfallis correct, the vehicie is ready to go back to the customer. Checking Torques on Fasteners Check torque using a forque wrench set tothe minimum spe- ification for that fastener. If the fastener does not rotate, he fastener torque has been maintained. If the fastener rotates, ‘remove it to determine ifithas a threadiocking agent, IF it has a threadlocking agent, clean all material from the threaded nole. Replace the fastener with a new one or clean the original fastener threads and apply the appropriate threadiocking product, Install and tighten the fastener to spe- ification, IF the fastener does not use a threadlocking agent. install and tighten to specication Magnetic Parts Trays Magnetic pars trays are common inthe service Facity. They are convenient and can Keep pars from becoming est during € repair procedure. However, hardened steel parts can become magnetized when held in magnetic parts trays, Metal fragments from normal wear are usually trapped in the ‘i ftar or by the magnetic drain plug. Magnetized pars in the tengine can retain these fragments, potentially causing acceler- ated engine wear and damage. Never place parts from inside the vahicle's powertrain on a ‘magnetic parts tray. REPAIR AND REPLACEMENT PROCEDURES Hardware and Threaded Parts Install thread repair inserts when threaded holes jn castings are sipped, damaged or not capable of withstanding specified foraue 4-4 2016 Dyna Service: Maintenance Replace bolts, nuts, studs, washers, spacers and small ‘common hardware if missing or damaged. Clean up or repair ‘minor thread damage with a suitable tap or die. Roplace all damaged ot missing hibrication stings Use LOGTITE 865 THREAD SEALANT on pipe fing threads Threadlocking Agents ‘Aways follow specific service manual procedures when working with fasteners containing preapplied threadlocking agents when fastener replacementis recommended. When reusing fasteners ‘containing threadtocking agents, thoroughly clean al fasteners and threaded holes. Always uso the recommended thread- locking agent for the specific procedure. Wiring, Hoses and Lines Replace hoses, clamps, electrical wiring, electrical switches or fuel ines if thay do not meet specifications, Instruments and Gauges Replace damaged of defective struments and gauges. Bearings Always use the proper lols and fixtures when servicing bear ings Antisricion bearings must be handled in a special way To keep out dirt and abrasives, cover the bearings as soon as they are removed from the package. When bearings are installed against shoulders, always verify that the chamfered side of the bearing faces the shoulaer Lubricate bearings and all metal contact surfaces before pressing into place. Only apply ovessure on the part of the ‘bearing that makes direct contac’ with the mating part. Install bearings with numbored side facing out Only remove bearings if necessary. Remmoval usually damages bbearings requiring replacement with new parts Bushings Do not remove a bushing unless damaged, excessively worn Or loose in its bore, Press out bushings requiring replacement. \When pressing or driving bushings, always apply pressure in line with the bushing bore. Use a bearingibushing driver of @ bar with @ smooth, flat end. Never use @ hammer to drive bushings. Verity that all ol holes ate propery aligned curing installation, Gaskets Always discard gaskets after removal. Replace with new gas- els, Never use the same gasket twice. Verify that gasket halos ‘match up with holes in the mating part. Be aware that sections. of a gasket may be used to seal passages, Lip-Type Seals Lip seais are used to seal oll orgrease and are usually installed with the sealing lip facing the coniained lubricant: Seal orient- ation, however, may vary under diferent applications. Do not remove seals unless necessary. Only remove seals to {gain access to other paris or if seal damage or wear dictates replacement Leaking oi! or grease usually means that 2 seal is damaged Replace leaking seals to pravent overheated bearings,‘Always ciscard seals after removal. Do nol use the same seal ‘wien O-Rings ‘Aways discard O-rings alter removal. Since many O-rings ae similar n size and appearance, alvays use new O-rings Kaeping nem packaged unti use to avoid contusion. To prevent leaks, lubricate the O-rings before installation withthe same type of ubricant as that being sealed. erly thet ol gasket, O- fing and seat mating surfaces are thoroughly clean before installation Gears ‘Aways check gears for damaged or worn teeth. Remove burrs and rough spots with @ honing stone or crocus clath before installation, Lubricate mating surfaces before pressing gears on shafts Shafts Wa shaft does not come out easily, check that all nuts, bolts (oF retaining rings have been removed. Check to see if other pars are in the way before using force to remove, ‘Shafts fted to tapered splines should be very tight. if shafts ‘are not tight, disassemble and inspec! tapered splines. Discard pars that are worn. Verify that tapered splines are clean, dry and free of burrs before putting them in place. Press mating parts together tightly Clean al rust from the machined surfaces of new parts, Part Replacement Awarninc Harley-Davidson parts and accessories are designed for Harley-Davidson motorcycles. Using non-Harley-Davidson parts or accessories can adversely affect performance, stability or handling, which could result in death or serious Injury. (00001b) ‘Aways install new genuine Harley-Davidson parts and accessories. This provides best service life and maintain ‘compliance with noise and emissions regulations Instaling non-Harley-Davidson, offroad or competition parts can Void warranty or result in an unsafe vehicle. CLEANING Protecting Rubber Parts Before cleaning, protect rubber parts (such as hoses, boots ‘and electrical insulation) from cleaning solutions. Use a grease- proof barrier material. Remove the rubber part ifit cannot be properly protected, Cleaning Process ‘Any cleaning method may be used as long as it does not resuil in parts damage, Thorough cleaning is necessary for proper pats inspection. Strip rusted paint areas to bare metal before priming and repainting Never use cleaners containing chlorine or ammonia on plastic parts. Chlorine causes parts to become distorted and britle resulting in cracks. Ammonia causes cloudiness and britieness in windshields and nor-painted parts to form a white haze. Rust or Corrosion Removal Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Uso buffing crocus cloth on highly polished parts that are rusted. Bearings Wash bearingsin a nonlammable petroleum cleaning solution Never use a solution that contains chlorine. Knock out pecked lubricant by tapping the bearing against a wooden block. Wash, bearings again Wea Using compressed air to "spin dry” bearings can cause bearing to fly apart, which could result in death or serious injury. (005056) Cover bearings with @ clean shop towel and allow to alr dry Do not spin bearings while they are drying, Never use com- pressed air to dry bearings. When dry, coat bearings with clean ol. Wrap bearings in clean paper. TOOL SAFETY _ Air Tools + Always use approved eye protection equipment when performing any task using ai-operated tools. + Onall power tools, use only recommended accessories, with proper capacity ratings, + Do not exceed air pressure ratings of any power tools. Placed bits against work surface before air hammers are operated. + Disconnect the air supply line to an air hammer before attaching a bit, + Never point an air too! at yourself or another person. + Protect yourself and bystanders with approved eye protec tion, Wrenches + Never use an extension on a wrench handle. + possible, always pull on a wrench handle and adjust, your stance to prevent a fall if something suddenly roleases. + Always keep the wrench squarely installed on the fastener + Never use a hammer on any wrench other than a ‘STRIKING FACE wrench, + Discard any wrench with damaged or battored points, + Never use a pipe wrench to bend, raise or lit pipe, 2016 Dyna Service: Maintenance 1-5Pliers/Cutters/Pry Bars + Plastic: or viny-covered pliers handles are not intended toact as insulation. Do not use them on live electrical cr- cuts. + Do not use pliers or cutters for cutting hardened wire unless they were designed for that purpose. + Always cut alright angles. + Donot use any pry bar as a chisel, punch or hammer. Hammers + Never strike a hammer against a hardened object, such ‘as another hammer, + Always grasp a hammer handle fimly, close to the end, + Stike the object with the full face of the hammer. + Nevar work with a hammer which has a loose head or cracked handle + Discard hammer if face is chipped or mushroomed. + Wear approved eye protection when using striking tools + Protect yourself and bystanders with approved eye protec- tion, Punches/Chisels + Never use a punch or chisel with a chipped or mush- roomed end. Dress mushroomed chisels and punches with a grinder + Hold a chisel or a punch with a tool holder if possible. + When using a chisel on a small piece, clamp the piece firmly ina vise and chip toward the stationary jaw. + Always wear approved eye protection when using these tools, + Protect yourself and bystanders with approved eye protec: tion, Screwdrivers + Donot use a screwdriver for prying, punching, chiseling, ‘scoring or scraping, + Use the right type of serewelriver forthe jab. Match the tip of a screwdriver to the fastener. + Do not interchange POZIDRIV, PHILLIPS or REED AND PRINCE screwdrivers, + Screwdriver handles are not intended to act as insulation, Do not use them on lve electrical circuits + Donot use a screwdriver with rounded edges because It will sip. Redress with a grinder. 4-6 2016 Dyna Service: Maintenance Ratchets and Handles + Periodically clean and lubricate ratchet mechanisms with 3 light grade oll, Do not replace parts individually. Rebuild ratchets withthe entire contents of service kil + Never hammer on a ratchet or put a pipe extension on a ratchet handle for added leverage, + Always. support the ratchet head when using socket ‘extensions. Do not put your hand on the head or you may interfere with the action of its reversing mechanism. ‘+ When breaking a fastener loose, apply a small amount of pressure as a test to make sure that the ratchet gear ‘wheel is engaged with the paw! Sockets + Never use hand sockets on power oF impact wrenches, Select only impact sockets for use with ai or electric impact wrenches. + Select the right size socket forthe job, + Aways keep: the wrench or sockel squarely on the fastener + Replace sockets showing cracks or wear + Keep sockets clean, + Aways use approved eye protection when using power orimpact sockets Storage Units + Donotopen more than one loaded drawer at atime. Close each drawer before opening another to prevent ine cabinet from unexpectedly tpping over. + Glose lids and lock drawers and doors before moving storage unis + Do not pul on a too! cabinet. AWays push fool cabinets in tron of you + Sette rakes on he locking casters alter the cabinet has been raed into positionFUEL AND OIL 1.3 FUEL ‘Always use a good quality unleaded gasoline, Octane ratings are usually found on the pump. Refer to Table 1-1 PN Avoid spills. Slowly remove filler cap. Do not fill above bottom of filler neck insert, leaving air space for fuel expansion. Secure filler cap after refueling. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00028a) Use care when refueling. Pressurized air in fuel tank can force gasoline to escape through filler tube, Gasoline is extremely flammable and highly explosive, which could result in death or serious Injury. (00029a) Modem service station pumps dispense a high flow of gasoline into a motoreycie fuel tank. This can cause air entrapment and pressurization, Table 1-1. Octane Rating raring | 31 G5 RON) Pump Octane (R+MY2 GASOLINE BLENDS ‘Your motorcycle was designed fo got the best performance and efficiency using unleaded gasoline. Most gasoline is blended with alcohol andfor ether to create oxygenated blends. The type and amount of alcohol or ether added to the fuel is Important NOTICE ‘Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine damage andlor equipment malfunction. (00148) + GasolingIMETHYL TERTIARY BUTYL ETHER (MTBE) blends are a mixture of gasoline and as much as 15 per- cent MTBE. Gasoline/MTBE blends use in your motorcycle is approved + ETHANOL fuolis.a mixture of ethanol (grain alcohol) and Unleaded gasoline and can have an impact on fuel mileage, Fuels with an ethanal content of up to 10 percent may be used in your motorcycle without affecting vehicle Performance. US. EPA regulations currently indicate that fuels wih 15 percent ethanol (E15) are restricted from use In motorcycles at the time of this publication, Some motorcycles are calibrated to operate with higher ethanol concentrations to meet the fuel standards in certain countries. + REFORMULATED OR OXYGENATED GASOLINES (RFG) describes gasoline blends that are specifically designed to buin cleaner than other types of gasoline This results in fewer tailpipe emissions. They are also formulated to evaporate less when filing the tank. Refor: mulated gasolines use additives to oxygenate the gas, Your motorcycle will run normally using this type of fue! Harley-Davidson recommends using it whenever possible as an aid to cleaner air in our environme Do not use racing fuel or fuel containing methanol. Use of these fuels wil damage the fuel system, + Using fuel additives other than those approved for use by Harley-Davidson may damage the engine, fuel system and other components ‘Some gasoline blends might adversely affect starting, driveab- lity 0 fuel efficiency. if any ofthese problems are experienced, try a diferent brand of gasoline or gasoline with & higher octane blend: ENGINE LUBRICATION Prue Prolonged or repeated contact with used motor oil may bbe harmful to skin and could cause skin cancer. Promptly, wash affected areas with soap and water. (00358b) Acaution fengine oil is swallowed, do not induce vomiting. Contact a physician immediately. In case of contact with eyes, Immediately flush with water. Contact a physician ifirrita- tion persists. (00357¢) NOTICE Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a) Engine ol is a major factor in the performance and service life of the engine. Use the proper grade of ol for the lowest tem- perature expected before the next all change, Refer to Table 1-2. This motorcycle was originally equipped with GENUINE HARLEY-DAVIDSON H-D 360 MOTORCYCLE OIL 20W50. H-D 360 is the preferred oll under normal operating conditions. If operation under extreme cold or heat are expected, refer to Table 1-2 for alternative choices IF HED 360 is not available, add ol certified for diesel engines. Acceptable designations include: CH-4, Cl-é and CJ-4. The preferred viscosities, in descending order are: 2050, 1540 ‘and 10W40) At the first opportunity, see an authorized dealer to change back to 100 percent Harley-Davidson cil 2016 Dyna Service: Maintenance 1-7‘Table 1-2. Recommended Engine Oils Screamin’ Eagle SYN3 Full Synthetic |Motoreycte Lubricant ‘Above 30 °F (-1 °C) ‘Genuine Harley-Davidson H-D 360 Motorcycte Oi Genuine Harley-Davidson H-D 360 Motorcycle Oi ‘Genuine Harley-Davidson H-D 360 | Motorcycle Oil WINTER LUBRICATION Change engine oil often in colder climates. if motorcycle is frequently used for trips fess than 15 mi (24 km), in ambient ‘temperatures below 60 °F (16 °C), reduce ol change intervals, to 1800 mi (2400 km), NOTE Lower ambient temperatures require more frequent oll changes. Water vapor is a normal by-product ef combustion. During cold- Weather operation, some water vapor condenses to liquid form 4-8 2016 Dyna Service: Maintenance ‘Aoove 40 C) | HD 360 | Above 60 °F (16 °C) Poor HD 360 Above 80° (27°C) “Poor HO 360 Below 40 °F (4 °C) Excelent ‘on the coo! surfaces inside the engine. In freezing weather this water becomes slush or ice. if the engine is not warmed to ‘operating temperature, accumulated slush orice blocks the oil lines and causes engine damage. Over time, water will accu- ‘ulate, mix withthe engine oll and frm a sludge that is harmful {0 the engine. It the engine is allowed ta warm to normal operating temper- ature, most of the water evaporates and exits through the ‘crankcase breather.MAINTENANCE SCHEDULE 1.4 GENERAL Use the quick reference maintenance chart for torque values, — lubricants or cross references to maintenance procedures, ‘Ateach regular service interval, perform the required mainten- Refer to Table 1-4. ‘ance, Refer lo Table 1-3. Use the lubricants, greases and sealants table to identify ‘maintenance supplies. Refer to Table 1-5 ‘Table 1-3. Regular Service Intervals: 2016 Harley-Davidson Dyna Models cesmentne veces | heck orev |X rom —e_ | heck offoriwiea] x x x |_| aa TEEPE Pee Pee pe Pd ee Pai | al 5 x T © x Lubricate steering head | ie: aT peewee | eT chad wine otottok | zt x x Pa \lower bracket pinch bolts | | [Check torque on front fork: x x x ] x x Sot race phate | | pet wich Bais Tx =I x x = y pets | | | | heck aut nd bile ee pe pe pe ef ee ee ows cone, | | Checkup andres |X % z act hang sow x ches cachiernaeta | =T x x x je [eae Be Seen |i chek rast oara |X x x x x [hae aeocer cre | | {orn \ ; Irae a cane a | aT EER PE ROR ee a wre [ | [Pe | iReooonneclaiter| x [x [x [x |e pe pe |x] x [x [x [ae |Replace primary chaincase |X * mal | x x x ria | Roscoe tannin | 3 ey ah | oe | _ || espe bale wan ee ee ee a Ee OR OY te [impacto moat | 1 =] xp (teers | cual a. Tnwearetakenudsany’ x |X ee p eye pe] FS | ied ea bakeoowe |e e pize cover sre re ce ae } - 1 Inspect brake pads and |X x x x x * * | x x x x ‘inca or wer | c ‘Check front axle pinch bott x x x x ‘rue: PUD a Pes Wwe ll TS [heck rte co x x x x /iRe ‘Shiner ae ba [emetoesenaeeve |X ¥ 5 x x [128] 2016 Dyna Service: Maintenance 1-8Table 1-3. Regular Service Intervals: 2016 Harley-Davidson Dyna Models ‘Check brake master einer (Sexe atc | Check ABS moaie(EHCU)) x 12, aro batiorue ‘Ghocktorque of ABS brake |X x x [ae ine have nas der omer “ork took al osect and iia iy ze ‘sand (Greek eich adjustment x [2a [Check just and brcate [brake sr sen eontols | Check rear wheel spokes (ore if eauped) ‘Shack ear to ores, Inept ews inspect na brite 63° rent beongs| Inspect ive Dal ond sroexes, ast et ‘Check eer ae ul ore ‘Chock rear exhaustbvackal) x | ® x x x x [ize atone at rarsmicsion | ‘Check rer exaust trackel! x x x x x (hae ‘eck at remiss | | Cheak bar. emia 7 torque, and clan comer | | (Ss annua, piace spark pli evry | tuo yours evr 20009 (4.000 km). whichever ‘comes fs [Rebull ont fork I I I Feplace ue ter lent | |every 100,000 my (160.000 co sd * | , x p= pe) 7) ey) eye] [ponent ane yom uncon | ‘noTEs: 7 Porrm anual or aspen nora, whichavar comes es 2 Should be pertormes by an authaian’ Karey Davidson deal, unless you have the proper tools, ervoe data and sre mechsnicaly| ‘aie. 5, ariam poke eson hahah 00 100), 200 600) 2,00 (920008) rs reve 180001 | (24.000 kn intoval rreaRor No al venice are aque win spoke neds. Const appropriate pic senrse manual «4 Parormmaensnee more aauerdy i savre rig condos ech as enforre pettus envrrmers, Moura ‘rough roads. ong storage cnctions, sot urs, hoavyslapgo Wai Poa ol Guy), | 5 Replace DOT 4 base Rd a fs sata) every to year 6, For torque insiuctions, see Shop Practices inthe service mena | 7 Disaserbl, sree ar npect every 30,000 (4,000 Kn) 5 leassembl. inspect. rebut fr ad esac oko every 0000 mi 80.00 km). Nore Whenever @ vehicle is in for maintenance: + Abvays check for and complete open recalls and product, programs. + Aways verity thatthe latest calibration is installed. 4-40 2016 Dyna Service: MaintenanceTable 1-4. Quick Reference Maintenance and Torque Chart Air cleaner |Alr cleaner cover bracket screw torque ‘Air cleaner cover screw torque ‘ADHESIVE for air cleaner cover screw Axle nut [Torque ror | Front axle pinch bolt (FLD) Front axle cap fasteners (All ut FLD) Axle nut torque (rear) terminal torque Brake fui resorvoirlevel Type |dinspect sight glass." Proper fuld level “fui is low, remove is reservoir cover and re- inspect, Visual inspoc- tion on FLD is accept able Master cylinder cover screw torgue: front Mast inder cover screw torque: rear ‘Handlebar clamp screw torque | ‘Master cylinder and caliper banjo bolt torque ‘ABS ECHU banjo bolt torque ‘ABS brake line Mare nut torque "Minimum brake pad thickness (Minimum brake dise thickness 7 32 play al adjuster sorew Brake pads and discs | Gutoh adjustment | ‘Adjuster screw locknut torque Free play athandlever ‘Clutch inspection cover torque Handlebar clamp screw torque = |LUBRICANT > | Hand control madule housing serew torque [eich and rete abies [Drive belt bottom of belt strand With motorcycle resting on jiffy stand without rider 1/4-8116 in (6.47.9 mm) = __jerluggage: Engine idle speed Idle speed Engine ol and filter Drain plug torque 36-60 in-bs (4.1-6.8 Nm) =. ~ LOCTITE 243 MEDIUM STRENGTH THRI “1196-118 in (1.63.2 mm) Bqti24L) | See 2.18 FRONT FORK 40-60 invtbs (4.5-6.8 Nm) LOCKER AND SEALANT (biue) 18-22 ftlbs (24.4-29.9 Nm) 182-180 in.ibs (14.9-20.3 Nm) [DOT 4 hydraulic brake fluid Front:1/8-3/8 in(3.2-9.5 mm) below gasket surface Rear: 1/4-1/2 in (6.4-12.7 mm) 6-8 inibs (0.7-0.9 Nm) '60-80 in-Ibs (6.8-9.0 Nm) _ [17-22 ft-lbs (23 1-29.9 Nm) ibs (189-24.4 Nm) 120-144 in-bs (13.6-16.3 Nm 0.04 in (1.02 mm) ‘See stamp on side of disc yiwn SS 72-120 ins (3.1-13.6 Nm) 84-108 inns (95-122 Nm) [00-20 into (68.9.0 Nm) (WARLEYUBE SSS 36-45 indbs (40-51 Nm) "| Upward measurement force applied at midpoint of 10 i. (4.5 kg) 950-1050 RPM 14-21 fs (190-28.6 Nm) Hand-ighton F230 tr afer gasket contact (30-35 ft-lbs (40.7-47. 5Nm) 30-35 felbs (40,7-47.5 Nm) Front fore Lower bracket pinch bolts Upper bracket pinch bolts => Front fork ol = | Amount Type Taian |Lubncant capacity Primary chaincase drain plug toraue HHD-ERI2 = |0.036-0.043 in (0.97-1.09 mm) TYPE 'E HYDRAULIC FORKOL 32 02, (0.95 L) _ 14.2 fabs (180-385 Nm) 12-18 ftbs (16.3-24.4 Nm) 2016 Dyna Service: Maintenance 1-11Table 1-4. Quick Reference Maintenance and Torque Chart, — —— Front 30 psi (207 KPa) Fite condition and pres- [Pressure with or without passenger |sure All except FXDF, FLD and FXDWG Rear; 40 psi (276 kPa) | Pressure with or without passenger Front: $8 psi (282 KPa) FXDWIG Rear: 40 psi (276 KP) Pressure with or without passenger | Front: 36 psi (248 kPa) FXDF, FLD Rear: 40 ps (276 KP) ‘Wear Replace tre if 1/82 in (0.8 mm) or less of ead | pattern remains ‘Transmission lubricant Lubricant level Dipstick between ADO and FULL marks with | motorcycte on jfy stand and dipstick screwed in [uni O-ring contacts case | ibrar pe and capaciy® FORMULA TRANSMISSION AND PRIWARY CHAIN LUBRICATION SYN3 20W50 OL Maxum 3202 (095) [Transmission drain plug torque 14-21 ft-lbs (19.0-28.5 Nm) [Dies trae 26.75 nibs (2.68 5 Vm) [Wal pakes | Spote ip trao 55 Inds (62 Nn) | |¢ Capacity is approximate. When changing lubricant, intially add 28 oz (0.83 L), Check and fil as necessary. * Capacity is approximate, When changing ol, intially add less than specified. Check and fil as necessary. Table 1-5. Lubricants, Greases, Sealants em PARTNUMBER |PACKAGE | 3M 847 Adhesive ~(021200-19718* |S a2 ube ‘3M General Purpose Adhesive Remover | 15.02 aerosol - ‘Anti-Seize Lubricant '98960.97 1 oz squeeze tube ‘CCI #20 Brake Grease /42830-05 ‘squeeze packel (included in master cylinder rebuild kt), [DOT 4 Brake Fluid 8 8853-98A 12 oe bottle [Dow Coming Moly 44Grease (94674-99 2 0 packet | Electrical Contact Lubricant [11300004" [1 02 squeeze tube __| [Formos Tenaissin and Pinay Ghincase 9051-05 Tat botte Lubricant | G40M Brake Grease |squeez | ‘Genuine Harley-Davidson Extended Life Antifreeze ‘and Coolant |Gonuine Haley Davidson FD 360 20050 1 gal container ‘Motorcycle Oi | Harley-Davidson Adhesive (Griplock) = '90830.05 110.9 tubo. Harley-Davidson High Performance Sealant - Gray ‘99650-02 11.9 02 squeeze tube on Leather Dressing (99261-81V ez ean .on Seal Grease 711300005, Voz tube HarleyLube __94968-09, 1/4 o2 needle dispenser Hylomar Gasket and Thread Sealant ~_|99653-85 3.0 02 tube locker and Sealant (purple) 99811-97 |G ml tube 142 2016 Dyna Service: Maintenance‘Table 1-5. Lubricants, Greases, Sealants. Loot 243 Medium Strength Threadocker and Sealant (ove) 9642-97 [6m tube 71700005 [50 mt be ‘Loctite 246 Medium StengthiHigh Temperature Threadlockor — (blue) Lotte 262 High StenginTheadlocker and So a Loci 271 Figh StrenathThreadiocker and Sealant (ed) | == Lb 477100006 «50 mL battle - Lodite 417 Prism Instant Adhesive =f —Ty - Lect 420 Super BonderAchesive j Locite 565 Thread Sealant ~jeeetea7 (Smite [Lecite770PiemPimer SC i Lecite 7649 CleanerPrmer : e806890 1.75 oz bolle | Scwamin’ Eagle Assombiy ibe 11300002 A oz tube 7 Screamin’ Eagle SYNG Full Syrtic Motoraycio "e3624-03000T + at bote : Lubnont 20150 | Special Purpose Grease 867-8714 oz eanidge Type "€" Hydric Fork jezso002 1Gazbowe : Whee! Bearing Grease : 9085589 1 bean | [sesss-c2[tozcanidge SSS | Not a Harley-Davidson part number Maintenance 1-13ENGINE OIL AND FILTER 1.5 CHECK ENGINE OIL LEVEL ee Prolonged or repeated contact with used motor oil may be harmful to skin and could cause skin cancer. Promptly wash affected areas with soap and water. (00358b) (QT mark, add only enough oil to bring the level tothe FULL HOT mark. Do not overfl NOTICE Do not overfill oil. Doing so can result in oil carryover to the air cleaner leading to equipment damage andlor equipment malfunction, (00190b) NOTES + Ollfevelcan be checked with motoreyele upright oron jiffy, stand. Both marks are on the same side of the diastick Carefully read dlpstick when checking of level. + Check engine oil evel at each complete fuel refi Oil Level Cold Check 1. Place vehicle on level ground resting on the jify stand, 2, See Figure 1-1, Remove filer plugidipstick. Wipe of the dipstick, Insert he dipstick and lighten inte the fill spout. NOTE level on @ cold engine should never be above the midway point, 3. See Figure 1-2. Remove filler plug/dipstick and check oil level. The correct ol levelis midway (2) between the ADD QT (1) and FULL HOT (3) marks on the dipstick. NOTE {Toil level is at or below the ADD QT mark, add only enough Cio bring the level midway (2) between the ADD QT and FULL HOT marks. Never bring the level to the FULL HOT mark on 8 cold engine Oil Level Hot Check NOTICE Do not allow hot oll level to fall below Add/Fill mark on dipstick. Doing so can result in equipment damage and/or equipment malfunction, (00189a) NOTE Perform engine oi level hot check anly with engine ail at normal operating temperature. 1. Ride motorcycle until engine oil reaches at least 200 *F (93°C) or higher. Allow engine to idle for 1-2 minutes. Tum off engine. 3. ‘See Figure 1-1. Remove filer plugidipstick. Wipe off the lipstick. Insert the dipstick and tighten into the fil spout. 4, See Figure 1-2, Remove filler plugidipstick and check oil level. Ol jevel must register between the ADD QT (1) and FULL HOT (3) marks. If ol level is at or below the ADD 41-14 2016 Dyna Service: Maintenance Figure 1-1. Filler Plug/Dipstick CHORE 4. ADD QT (lower) mark | 2. Cold check level 3._ FULL (hot check) mark Figure 1-2, Engine Oil Dipstick CHANGING OIL AND OIL FILTER [PART NUMBER ‘TOOL NAME [o-42311 OIL FILTER WRENCH HD-44067A [FASTENER Engine of rain pu 1421 febs |19.028.5 Nm Change engine ol at he frst 1000 mi (1600 km) ora new engine. Mer te inal servic, change ol at reguer intervals inrormal service at wam or moderate temperalures. Rater o Tablets‘Change oll at more frequent intervalsin cold weather or severe ‘operating conditions, See 1.3 FUEL AND OIL, Winter Lubrica- tion, Twin Cam equipped vehicles require the premium cil fie, avaliabe in chrame (Part No, 63798-99A) or black (Part No. 63731-998). enc) Be sure that no lubricants or fluids got on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the ‘motorcycle and death or serious injury. (000474) NOTICE Do not switch lubricant brands indiscriminately because ‘some lubricants interact chemically when mixed. Use of Inferior lubricants can damage the engine. (00184a) 1. Run motoreycle until engine is at normal operating termper- ature. Turn off engine. 2. Remove filer plug/dinstick NOTE Replace drain plug O-ring if damaged, 3, See Figure 1-3, Remove the ol drain plug (2) and O-ring Allow oil to drain completely, NOTICE Use Harley-Davidson oil filter wrench for filter removal. ‘This tool can prevent damage to crankshaft position sensor and/or sensor cable, (00192) 4. Remove the oil fiter using OIL FILTER WRENCH (Part No. HD-42311) or OIL FILTER WRENCH (Part No. HD- 44087A) and hand tools. Do not use with air toots. Clean the ol fiter mount flange. See Figure 1-4. Install new oil iter. ‘a Lubricate gasket with a thin fim of clean engine oil b. Install new il fier. ©. Hand-tighten oil fiter one-half to three-quarters of 2 tum after gasket first contacts fiter mounting surface. Do NOT use ail fiter wrench for installation. 7. Install engine oil drain plug and O-ring, Tighten to 14-21 ftbs (19.0-28.5 Nm) NOTE Use the proper grade of ol forthe lowest temperature expected before the next olf change. Refer to Table 1-2 fr recommended ail 8, Add an intial volume of engine oil. Refer to Table 1-6 Table 14, Initial Oil f 1" Engine inital ot fil [25 24 9. Verify proper cil level. See 1.5 ENGINE OIL AND FILTER, Check Engine Oil Level 2. Perform engine o| level cold check 'b. Start engine and carefully check for ol leaks around drain plug and cil fiter c. Perform engine ol level hot check. Figure 1-3. Engine Gil Drain Plug (left side under transmission) Figure 1-4. Lubricating New Oil Filter Gasket Maintenance 1-15AIR CLEANER AND EXHAUST SYSTEM 1.6 REMOVAL, ALL BUT HO103 1, See Figure 1-5. Remove cover serew (1) and air cleaner cover (2), 2. Gently pull both breather tubes (6) from the fier element a 3. Slide speed nut (12, all but FXDB) to the left to allow access fo third screw. Remove three screws (4), bracket (6) and fter element, 4, Replace the filer element if damaged or i fiter media cannot be adequately cleaned Gently pull the breather tubes from the breather bolts on the backplate. rs Do not use gasoline or solvents to clean filter element, Flammable cleaning agents can cause an intake system fire, which could result in death or serious injury. (001013) Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed alr. Never tase your hand to check for air leaks or to determine air flow rates. (00061a) 446 2016 Dyna Service: Maintenance 6. Clean fier element. ‘a. Wash the paperiwire mesh air fiter element and breather tubes in lukewarm water with 2 mild deter ‘genl, Do not strike filler element on a hard surface to dislodge dirt 1b. Allow fiter to either air dry or, from the inside, dry with low-pressure compressed ait. Do NOT use air cleaner filter oll on the Harley-Davidson paperiwire mesh air fiter element ©. Hold the fiter element up to a strong ight source. If light is uniformly visible through the element, is sufficiently clean Inspect seal ring an cover for cracks of tears. Vanity that cover seals tightly to backplate, Replace as required, Inspect breather tubes for damage. Replace if necessary. NoTES The breather tubes direct crankcase vapors into the air fiter element. By providing effective recirculation of crankcase vapor, the tubes serve fo eliminate the pollut- fants normally discharged from the crankcase Air cleaner mounting without installation of the breather tubes allows venting of crankcase vapors inla the atmo- ‘sphore. This vapor venting violates emissions regulations. Wipe inside of air leaner cover and backplate with damp cloth to remove dust. California models only: Make sure trap door swings freely.4. Cover serew 7. Filtor element | 2 Rircleaner cover 8. Breather boit (2) (metric) |B Seat ring 8. Backplate 4 Screw (3) 10. Gasket | 5. Bracket 11. Gasket 6._ Breather tube (2) 42. Speednut - Figure 1-5. Air Cleaner Assembly (typical) INSTALLATION, ALL BUT HO103 Air cleaner cover bracket | 40-60 Intbs 45-68 Nm ‘Aircleaner cover screw | 36-60in-lbs | 4.1-68Nm_ 1. See Figure 1-6. Position new gasket on fter element. “Make sure that gasket holes are aligned with screw holes 2. See Figure 1-5. Atach breather tubes (6) to breather screws (8) on backplate. Install fiter element (7) anc bracket (5) using three screws, (4). Tighten to 40-60 in-ibs (4.5-6.8 Nm). Slide speed nut (12, all but FXDB) to the right and into place. Insert breather tubes into holes in fier element. Install air cleaner cover (2), Apply a drop of LOCTITE 243 MEDIUM STRENGTH ‘THREADLOCKER AND SEALANT (blue) fo threads. of cover screw (1). 1b. Install cover screw. Tighten to 36-60 in-bs (4.1.6.8 Nm) REMOVAL, HO103 _ Figure 1-6. Element Gasket See Figure 1-7. Remave inser screws (1) and coverinser @) Remove cover screw (3) and air cleaner cover (4). Remove screws (6) and fiter element (6) from adapter plate (7). 2016 Dyna Service: Maintenance 1-17EG Do not use gasoline or solvents to clean filter element. Flammable cleaning agents can cause an intake system fire, which could result in death or serious injury. (0010 1a) A. Inspect fiter element. See 1.6 AIR CLEANER AND. EXHAUST SYSTEM, Removal, All But HO103. Replace if damaged ori fiter media cannot be adequately cleaned, Insert screw (2) Cover insert | Cover screw Air cleaner cover Screw (3) Filter element Adapter plate Backplate Figure 4-7. Air Filter, HO103 1 2 3 4 5 6 7. 8 INSTALLATION, HO103 im | ToRave vate Fitter element screw | S5-60 indbs | 5.2-6.8Nm Air cleaner cover screw [36-60 Inds 4.1-6.8 Nm Coverinsetsciew | 27S2indbs | 3.138 Nm 1, See Figure 1-7, 1-48 2016 Dyna Service: Maintenance 2. Install ter element (6) onto adapter plate (7) 3. Apply LOCTITE 243 MEDIUM STRENGTH THREAD- LOCKER AND SEALANT (blue) to screws (5). Install screws. Tighten to 55-60 indbs (5:2-6.8 Nm) 4. Install air cleaner cover (4) 2. Apply a drop of LOCTITE 243 MEDIUM STRENGTH THREADLOCKER ANC SEALANT (blue) to threads of cover screw (3) ©. Install cover screw. Tighten to 36-60 indbs (4.1-5.8 Nm) 5. Install cover insert (2) and insert screws (1). Tighten to 27-32 inelbs (3.1-3.6 Nm). CHECK EXHAUST SYSTEM LEAKAGE Check exhaust system for loaks al every scheduled service interval 4. Check entire exhaust system for loose or missing fasteners ‘and damaged pipe clamps or brackets. Check exhaust system for obvious signs of leakage such as carbon tracks, al pipe joints 2. Check for loose or damaged exhaust shiolds, Replace or repair as necessary. 3. Start ongine, cover mufier ends with clean, dry shop. towels and listen for audible signs of exhaust leakage 4. Correct any toaks detected Exhaust System Leakage Han exhaust system leakis evident al a muffier orhheader pipe ‘connection, disassemble and clean all mating surfaces. See 4.15 EXHAUST SYSTEM Replace any damaged components. + Ifleak continues, disassembie and apply Permatex Utira Copper, LOCTITE 5920 FLANGE SEALANT or equivalent + Assemble components. Wipe off any excess sealant. + Follow sealant product instructions. Allow adequate curing time before operating vehicleTIRES AND WHEELS 1.7 TIRES _ Match tires, tubes, rim strips or seals, air valves and caps to the correct wheel. Contact a Harley-Davidson dealer. Mismatching can lead to tire damage, allow tire slippage ‘on the whee! or cause tire failure, which could result in death or serious injury. (00023c) Noes + Tubeless tires are used on all Harley-Davidson cast and disc wheels, Tire sizes are molded on the tre sidewall. Inner tube sizes are printed on the tube, New tes should be stored on @ horizontal tre rack. Avoid stacking new tres in a vertical stack. The weight of the Stack compresses the tires and closes down the beads. ‘ABS equipped motorcycles must always use propery inflated tires and whoels that are the same as the original equipment, The ABS system monitors rotational speed of the wheels through individual whee! speed sensors (a determine the application of ABS, Different dlameter wheels or tres can: + Alter the rotational speed which can upset the calibration of the ABS. + Adversoly affect its abiliy to detect and prevent lockups. (Qperating with inflation pressure other than those specified in Table 1-7 can reduce ABS performance. (Check tire pressure and tread: + As part of the pre-ride inspection. + Atevery scheduled service interval 1. Inspect each tre for punctures, cuts and breaks. 2. Inspect each tire for wear. Replace tires before they reach the tread wear indicator bars. PGs) Be sure tires are properly inflated, balanced, undamaged, and have adequate tread. Inspect your tires regularly and, see a Harley-Davidson dealer for replacements, Riding with excessively worn, unbalanced, improperly inflated, overloaded or damaged tires can lead to tire failure and, adversely affect stability and handling, which could result, Jn death or serious injury. (000146) NOTE Missing indicator wear bars represent less than 1/32 in (0.8 ‘mm) tread pattern depth remaining, 3. Check tre pressures when ties are cold, Compare results, to Table 17, Note Harley-Davidson does not perform any testing with only nitrogen in tires. Harley-Davidson neither recommends nor discourages the use of pure nitrogen to inflate tires. Table 1-7. Specified Tires | MODEL | woUNT ‘SE | SPECIFIED TIRE | PRESSURE (COLD) | esl a i [FXDB,FXDBC, Front 13 | Michelin Scorcher “31” 10/9081 30 206 FXDBR, FXOL "Rear 7 Michelin Seorcher “31” 160/70817 40 216 FXOF Front | 16 - Dunlop D427F 130/90B16 36 248 Rear 16 Dunlop 0427 180/70816 40 276 FXDWG Front a Michelin Scorcher "31" 80/90-21 38 262 Rear 7 Michelin Scorcher "31" 180/60817 40 26 FLD Front 18 Dunlop D402F 130770518 36 248 Rear 7 Dunlop 0401 160/70817 40 276 TIRE REPLACEMENT Awanninc Use only Harley-Davidson specified tires. See a Harley- Davidson dealer, Using non-specified tires can adversely affect stability, handling or braking, which could result in death or serious injury. (00024b) Awarninc Roplace tire immediately with a Harley-Davidson specified tire when wear bars become visible or only 1/32 in (0.8, mm) tread depth remains, Riding with a worn tire could result in death or serious injury. (00090c) Harley-Davidson tires have wear bars that run horizontally, ‘across the tread, When a tice is worn fo the paint thatthe wear 2016 Dyna Service: Maintenance 1-19bars are visible, or 1/32 in (0.8 mm) read depth remains, the tire can’ Be more easily damaged leading to tre failure Provide reduced traction. ‘Adversoly affect stability and handling, Dunlop See Figure 1-2, Arows on te sidewats pinpoint locaton of wear ba ndcstors. See Figue 1-8. Tread wear indicator bars appear on Dunlop tre vead surfaces when 1/92 in (0.8mm) or less te tad remains, Alay replace thes beloe the tread weer idictoe bars appear: Michelin See Figure 1-10, Michelin Man on Micheli tre tad side (nest to scewal) pinpoints location of wear bar indicators. Aways replace tres before the tread wear ndcator bars appear See Figue 1-1. Tread wearindcatr bars appear on Michatn te ead surfaces when 1/22 in (0.8 mn) oles te teed New tes are needed it Te wear indicator bars become visible onthe tread sur- faces. Tie cords or fate become visible trough eracked side- walls snags or deep cuts ‘bump, bulge o pit inthe tres founa + Puncture, cut or other damage tothe tire that cannot be repaired Figure 1-8, Dunlop Sidewall Tread Wear Indicator Bar Locator 1-20 2016 Dyna Service: MaintenanceFigure 1-11, Michelin Tire Wear Bar Appearance WHEEL BEARINGS Nore Replace bearings in sets only. See 2.5 SEALED WHEEL BEARINGS. 11, Replace when beatings exceed end play service wear limit of 0,002 in (0.054 mm). 2. Inspect any time the wheels are removed. a. Inspect the play of the whee! bearings by hand while they are in the wheel . Rotate the inner bearing race and check for abnormal ‘c, Make sure that bearing rotates smoothly, 3. Check whee! bearings and axle spacers for wear and corrosion, Excessive play or roughness indicates wom bearings. WHEEL SPOKES PART NUMBER ‘TOOL NAME H-48985 ‘SPOKE TORQUE WRENCH HD-94681-80 ‘SPOKE NIPPLE WRENCH ne Spoke nipple 55 inibs OG ‘Spokes that are too tight can draw nipples through the rim fF distort hub flanges. Spokes that are too loose can continue to loosen when put in service, Either condition can adversely atfect stability and handling, which could result in death or serious injury. (002863) Ed Do not overctighten spoke nipples. Protruding spoke nipples can damage rim seal, resulting in rapid tire defla- tion, which could cause death or serious injury. (00611c) NOTICE When lifting a motorcycle using a Jack, be sure Jack con- tacts both lower frame tubes where down tubes and lower converge. Never lift by jacking on cross oll pan, mounting brackets, components or housings. Failure to comply can cause serious damage resulting in the need to perform major repair work. (005864) Identify Wheel Spoke Groups NOTE ‘Spokes are grouped in sets of four. 4. Raise the wheel 2, See Figure 1-12. Starting al the va first group of four spokes (1-4) tem, identify the 3, Using a different color for each spoke in the group, draw an alignment mark across the spoke nipple and onto the 4. Continue around the wheel marking the rest of the spokes the same as they were marked in the provious steps. Adjust Wheel Spokes NOTES + Do not tighten spoke more than one-quarter tum past alignment mark. If more tension is needed, label spoke ‘and check after completing rest of wheel. + Do not use the spoke torque wrench to loosen spokes. Use SPOKE NIPPLE WRENCH (Part No, HD-94681-60) to loosen spokes. 4, See Figure 1-12. Starting with the first group of spokes, loosen spoke (1) one-quarter tum using SPOKE NIPPLE WRENCH (Part No. HD-24681-80), 2. Using SPOKE TORQUE WRENCH (Part No. HO-48985), tighten spoke (1) to the value listed in Table 1-8 a, While tightening, if the torque wrenich clicks before the alignment marks align, continue to tum the spoke ripple until the marks align. b. If the marks align and torque specification has not ‘been reached, tighten the spoke nipple until the cor- rect torque Is achieved. Do not tur spoke nipple more than one-quarter tun past alignment mark, 3, Repeat previous two steps for spoke (4) n the same group, 4. Continue around the whee! checking spokes 1 and 4 until, all groups are done. 5, Repeat procedure for spokes (2, 3) in each group. NOTE When checking any spokes that were labeled, make sure (0 use the original alignment mark. 2016 Dyna Service: Maintenance 1-216 Check spokes, if any, that wore labeled as not reaching 7. True the wheel. See 28 CHECKING AND TRUING the proper torque value after tightening one-quarter tum’ WHEELS. past alignment mark Loosen spoke one-quarter {urn past original alignment Table 1-8. Spoke Nipple Torque Specification ‘mark using SPOKE NIPPLE WRENCH (Part No, HD- 94681-80). = | MINN TORGUE 1. While tightening, i the torque wrench clicks before ue [js ABR NHES G2 Ne the alignment marks align, continue totum the spoke ‘nipple until the marks align, ©. Ifthe marks align and torque specification has not been reached, tighten the spoke nipple until the cor- ‘eet torque is achieved. Do not turn spoke nipple more than one-quarter turn past alignment mark. Figure 1-12. Tightening Laced Wheels (typical) 4-22 2016 Dyna Service: MaintenancePRIMARY CHAINCASE LUBRICANT GENERAL ‘All madels have an automatic chain tensioner. For primary chain service procedures, see 5.4 DRIVE COMPONENTS. CHANGE PRIMARY CHAINCASE LUBRICANT |asTel ENER [Primary chaincase drain plug 14-21 fos 19.0-28.5Nm | Clutch inspection cover | screws 1, Run motorcycle unl engine is at normal operating temper- ature, Turn off engine, ean) Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid, Traction can be adversely affected, which could result in loss of control of the ‘motorcycle and death or serious injury. (000474) 2, Secure motorcycle upright (not leaning on jify stand) on a level surface. 3, See Figure 1-13. Drain primary chaincase. 4. Clean drain plug magnel. If plug has excessive debris, inspect the condition of chaincase components Install new O-ring on drain plug. Install drain plug, Tighten to 14-21 fhibs (19,0-28.5 Nm) Figure 1-13, Removalfinstallation of Chaincase Drain Plug 7. See Figure 1-14. Remove screws with washers (3) and teh inspection cover (2), 8, Remove seal (1). Wipe ol from groove in chaincase cover ‘and mounting surface. NOTICE Do not overfill the primary chaincase with lubricant. Overfiling can cause rough clutch engagement, Incomplete disengagement, clutch drag andior difficulty in finding neutral at engine idle. (00199) 9. Pour specified amount of FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT through clutch Inspection cover opening, Refer to Table 1-9, ‘Table 1-9. Primary Chaincase Lubricant Refill Capacity eae ae | Wet “| 10 Dy" ow * Quantity after complete disassembly. 10. Install clutch inspection cover and new seal: a, Thoroughly wipe all lubricant from cover mounting surface and groove in chaincase cover. b. See Figure 1-14, Position new seal (1) in groove in Clutch inspection cover (2). Press each of the nubs (on seal into the groove. Secure clutch inspection cover (2) with screws with captive washers (3) 4. See Figure 1-15. Tighten in sequence shown to 84- 108 in-ibs (9.5-12.2 Nm. 1. Seat | 2 Clutch inspection cover |__3.. Screw and captive washer (5) Figure 1-14. Clutch Cover 2016 Dyna Service: Maintenance 1-23Figure 1-18. Clutch Gover Torque Sequence 41-24 2016 Dyna Service: MaintenanceTRANSMISSION LUBRICANT CHECK TRANSMISSION LUBRICANT SSS ONAN] Transmission filer plugidip- | 25-75 inbs | 2.8-8.5Nm stick NOTE (Check transmission fluid with the motoreycle at ambient tem- perature 1. Park motoreycle on a level surface on jy stand. 2. See Figure 1-18, Remove transmission filler plugidipstick, Wipe dipstick clean, 3. Instalifiler plug/sipstick unt O-ring contacts the case. Do not tighten. 4. See Figure 1-17, Remove filer plugidipstick. Check lub- Ficant level on dipstick NOTICE Mixing mineral-based lubricants with SYN-3 in the trans- ‘mission can damage the transmission, (00452b) 5. Propercil level is between the Add (A) (1) and Full (F) (2) marks, Add only eriough lubricant to bring evel to between the A mark and the F marks. Refer to Table 1-10. 6. Instal filer plug/dipstick. Tighten to 25-75 intbs (2.8-8.5 Nm) Figure 1-16. Transmission Dipstick Location 1. Add (A) 2. Full (F) Figure 1-17. Transmission Lubricant Level ‘Table 1-10, Recommerded Transmission Lubricants QUANTITY *) ee ec a FORMULAt TRANSMISSION AND PRIMARY) 28 | 0.83 (CHAINCASE LUBRICANT | 'SCREAMIN'EAGLE SYN3FULLSYNTHETIC| 28 | 0.83 MOTORCYCLE LUBRICANT 20W50 | * Fill quantity for a transmission lubricant change. CHANGE TRANSMISSION LUBRICANT _ ees Transmission drain plug Transmission filer plugidip- stick IE VALUE 19.0-28.5 Nm 14-21 thibs: 25-78 indbs | 2.6-85Nm 1. See Figure 1-18, Remove transmission filer plug/dipstick ZN Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid, Traction can be adversely affected, which could result in loss of contro! of the motorcycle and death or serious injury. (000474) 2. See Figure 1-18. Remove transmission drain plug. Drain transmission, 3, Clean and inspect drain plug and O-ring, NOTICE Do not over-tighten filler or drain plug. Doing so could result in a lubricant leak, (00200b) 4, Install drain plug with O-ring. Tighten to 14-24 felbs (19.0- 28.5 Nm). Do not over-tighten. 2016 Dyna Service: Maintenance 1-25‘5. Fill he transmission with 28 oz (0.83 L) of recommended Harley-Davidson lubricant. Refer to Table 1-10. 6. Check lubricant level. Adé enough lubricant to bring the level between the add (A) and full (F) marks. See 1.9 TRANSMISSION LUBRICANT, Check Transmission Lubricant, 7. Install filer plug/dipstick. Tighten to 25-75 in-bs (2:8-8.5 Nm). 4. Engine ol drain plug and O-ring |_2._ Transmission drain plug Figure 1-18. 011 Pan 4-26 2016 Dyna Service: MaintenanceCLUTCH 1.10 ADJUSTMENT _ (Clutch adjuster screw jamnut 72-120 inbs| 8.1-13.6 Nm Clutch cable adjustment 120intbs | 136Nm | Jamnut | (Clutch inspection cover 84-108 in-bs | 9.5-12.2.Nm | NOTE Perform the clutch adjustment with the motorcycle at room temperature. Clearance at the adjuster screw increases as the powertrain temperature increases, IFadjusiment Is made with, powertrain hot, clearance at pushrod bearing could be insuf- cient with powertrain cold. Clutch slippage could occur. 4. Remove main fuse, 2, Stand motorcycle upright (not leaning on jify stand) on a level surface, 3, Remove clutch inspection caver from primary chaincase 4, Remove and discard seal ing from clutch inspection cover. 5. See Figure 1-19, Add free play to cable. 1a, Slide rubber boot (1) off cable adjuster. Loosen jamnut (3) and back away from cable adjuster. ©. Turn adjuster (2) to introduce a large amount of free play at hand lever. 6. See Figure 1-20. Loosen jamnut (1) on clutch adjuster screw, Turn adjuster screw (2) inward (clockwise) until lightly seates. 7. Back out adjuster screw one-half to one full turn. While holding adjuster screw, tighten Jamnut to 72-120 in-ibs, (8.1-13.6 Nm), 8 Squeeze clutch lever to maximum limit three times to set release mechanism 8 See Figure 1-19, Check free play . Tum cable adjuster (2) until slack is eliminated at hand lever, b. See Figure 1-21. Pull clutch cable ferrule (2) away from clutch lever bracket to check free play. Tun cable adjuster to obtain free play (4). Refer to table Table 1-11 10, See Figure 1-19. Hold adjuster and tighten jamnnut to 120 in-ibs (13.6 Nm). Cover cable adjuster mechanism with rubber boot. Table 1-11. Clutch Cable Free Play Free play dimension ‘in (1.8-3.2 mm) 11. Swab all lubricant from seal ring groove in chaincase cover. Press new sei ring into groove with nubs con- tacting ring groove wals. 42. See Figure 1-18. Secure clutch inspection cover. Tighten in sequence shown to 84-108 inslbs (9.5-12.2 Nm. 4. Rubber boot 2, Cable adjuster 3, Jamnut 4. Jamnut __2. Clutch adjuster serow Figure 1-20, Clutch Adjuster Screw 2016 Dyna Service: Maintenance 1-27Clutch cable Cable ferrule Clutch lever bracket Free play dimension Figure 1-21. Clutch Cable Fi 4-28 2016 Dyna Service: MaintenanceDRIVE BELT AND SPROCKETS GENERAL WARNING. Never bend belt forward into a loop smaller than the drive sprocket diameter. Never bend belt into a reverse loop. (Over bending can damage belt resulting in premature failure, which could cause loss of control and death or ssorious injury. (00338a) Inthe case of stone damage to belt, Inspect the sprockets for damage and replace as required. If replacing bolt, always replace both transmission and rear sprockets CLEANING a Keep dir, grease, oll, and debris off the drive belt and sprockets, Clean the belt with a rag slightly dampened with 2 light cleaning agent. INSPECTION Sprockets 1. See Figure 1-22. Inspect each tooth (1) of rear sprocket for a, Major teoth damage Large chrome chips with sharp edges ©. Gouges caused by hard abjects d. Excessive loss of chrome plating (see next step) 2. Check for wom chrome plating. Drag a sharp object across the bottom of a groove (2) using medium pressure. a. If sharp object slides across groove without digging in or leaving a visible mark, chrome plating is stil 004. b._Ifsharp object digs in and leaves a visible mark, itis cutting the bare aluminum. The chrome plating is 3. Replace rear sprocket if major tooth damage or loss of chrome exists, 4. Tooth 2. Groove Figure 1-22. Rear Sprocket Drive Belt See Figure 1-23. Inspact drive belt for: + Cuts or unusual wear pattems + Outside bevel wear (8). Some beveling is common, but it Indicates that sprockets are misaligned + Quiside ribbed surface for signs of stone damage (7). If cracks or other damage exists near edge of belt, replace belt immediately, Damage to center of belt eventually requires belt replacement. However, when cracks extend to edge of belt, failure is imminent *+ Inside (toothed portion) of belt for exposed tensile cords, (normally covered by nylon layer and polyethylene layer) Replace belt and transmission sprocket, + Signs of puncture or cracking atthe base of the belt teeth, Replace belt i either condition exists + Replace belt conditions 2, 3, 6 or 7 (on edge of belt) exist NOTE Condition 1 may develop into 2 or 3 over time. 2016 Dyna Service: Maintenance 1-28Figure 1-23. Drive Belt Wear Table 1-12. Drive Belt Wear Analysis ‘OK to run, but monitor condition. Replace belt and sprocke. jeplace belt if damage is on the edge. h iG ‘OK to run, but monitor condition CHECK DRIVE BELT DEFLECTION (Check detection: — _ + _ As part of pre-ride inspectior. + Atevery scheduled service interval. HD-25381-4 BELT TENSION GAUGE + With transmission in neutral Mpiliett ita nice peli WER ID Coe oe eC chced fins ce RT TENSION GAUGE at HOSSBLA) mn mt roy ie cause under-tensioned belts. Loose belts can fail due 10 “fatcheting” jumping tooth) which causes tensile cord * With the vehicle unladen: no rider, no luggage and crimping and breakage, ‘saddlebags, if equipped, empy. 1-0 2016 Dyna Service: MaintenanceTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before pro- ceeding, (002518) 1. Disarm securty system. Remove main fuse. See T8FUSES, Replacement 2. See Figure 1-28, Measure belt deflection using HD BELT TENSION GAUGE (PartNo. HD-35387-4) Side Owing (4) t0 0 (0 kg) mark (3). , Models equipped with belt deflection window: Fit bolt cradle (2) against Bottom of diva lt in ine wth belt detection window ¢.Allother models: Fit bet cradle (2) against bottom of dive bet halay between dive puleys 4. Press upward on knob (6) unl O-ring sides down to 10 (45 kg) mark () and old steady. 10 tb (4.5 kg) of force Amount of deflection eens 3, Measure belt deflection: Figure 1-25. Checking Belt Deflection 2. Models equipped with belt deflection window: Soo Figure 1-26, Measure belt deflection as viewed through belt deflection viewing window while holding gauge steady, Each deflection graduation is approx imately 1/16 in (1.59 mm). b. Allother models: See Figure 1-25. Measure amount Of deflection (4) whlle holding gauge steady. 4. Compare with specifications. Adjust as necessary. Refer, to Table 1-13, 5. Install main fuse. oO 1. Drive belt Belt tension gauge ADJUSTING BELT DEFLECTION Belt cradle a ae = Ob (0 kg) mark | O-ring | 10 Ib (4.5 kg) mark Knob Figure 1-24. Belt Tension Gauge 1. See Figure 1-27. Remove ret axle nut (2). 2016 Dyna Service: Maintenance 1-312. Adjust belt tension by tuning the axle adjusters (1) an equal number of turns to keep the wheel aligned unti the specification in Table 1-13 is achieved, 3, Install retaining ring (3) 4, Tighten axle nut (2) to 95-105 feibs (128. 8-142.4 Nm) 5, Tighten axle adjusters to 120-144 indbs (13.6-16.3 Nm), 6 Verity rear wheel alignment, See 2.9 VEHICLE ALIGN MENT. Check wheel bearing end play after tightening axle nut to specified torque. Excessive end play can adversely affect stability and handling and can cause loss of control, which could result in death or serious injury. (00285b) 7. Check whee! bearing end play, See 2.6 SEALED WHEEL BEARINGS, 4-82 2016 Dyna Service: Maintenance 1. Axle adjuster 2. Axle nut 3. Retaining ring Figure 1-27. Axle Adjusters (Loft Side Shown)THROTTLE CABLES 1.12 CABLE INSPECTION AND LUBRICATION ES: 35-45 nibs Switch housing screw 4.05.1 Nm 1. Release throttle cable tension. See 1.12 THROTTLE CABLES, Cable Adjustment 2. See Figure 1-28, Remove screws (1) to sepatate upper ‘switch Rousing trom the lower housing, 3. Unheok ferrules and cables from throtle grip. Remove throttle sleeve, 4, Inspect each cable. Replace cable assembly it cable is ‘rayed or kinked. 5. Inspect cable outer sheath from throtta grip to induction module. Replace as necessary. 6. Apply a light coating of graphite to handlebar and inside surface of housings. Replace throtle rip. 7. Pour two drops of HARLEY LUBE into cable housings. 8, Install switch housing. Tighten to 35-85 In-tbs (4.0-5.1 Nm) 2. Adjust tnotte cables CABLE ADJUSTMENT Operation Awarninc Before starting engine, be sure throttle control will snap back to idle position when released. A throttle control that prevents engine from automatically returning to idle can lead to loss of control, which could result in death or ser- ious injury. (00390a) Do not tighten throttle friction adjustment screw to the point where the engine will not return to idle automatically. ‘Over-tightening can lead to loss of vehicle control, which, could result in death or serious injury. (00031b) 1. See Figure 1-28, Loosen fiction screw (3) 2, Roll on and release thrattle grip (2). If throtla does not return fo closed (idle), inspect and adjust throttle cables. 2. With engine idling, tum handlebar stop 10 stop. If engine ‘speed changes, adjust throtle cables, Adjustment 1. See Figure 1-28. Loosen friction sorew (3). 2. Slide rubber boots off cable adjusters (6). 3. Loosen jamnuts (7) 4. Tum cabie adustersto shorten cable housings to minimum length 5. Point font whee! straight ahead. With engine OFF, rll throtle grip (2) fully apan, Hol in position 6 Gently ium cablé adjuster (6) on throttle cable (4) counter- clockwise Unt throttle cam (8) touches throttle cam stop (10), Release throttle grip, Tighten jamnut on throttle cable adjuster. 7. Turn handlebar full right lock, Turn cable adjuster (6) on {dle cable (5) to lencthen sleeve until end of cable housing touches spring (9) within cable guide (11). NOTE The throtily contol jpust operate freely when frant whee! is turned to night id eR fork stops. 8. Chedfcsjustinent. Twist and release throttle grip two or three fies, If Mhyottie does net return to idle, turn idle adjuster fo sherten sleeve until correct. Tighten jamnuts. 8, Slide rubber boots over cable adjusters. 2016 Dyna Service: Maintenance 1-33|. Serew (2) Throttle grip Friction serow Throttle (pull open) cable Idle (pull close) cable ‘Cable adjuster (2) oo nene 1-34 2016 Dyna Service: Maintenance 7. Jamnut (2) 8. Throttle cam 9. Spring 10. Throttle cam stop 11, Cable guide Figure 1-28. Throttle Cable AdjustmentCABLE AND CHASSIS LUBRICATION 1.13 GENERAL Inspect and lubricate the following items according to 1.4 MAINTENANCE SCHEDULE, Front brake hand lever (Clutch hand lever Throttle control cables ‘Throttle control grip sleeve Clutch cable Steering head bearings si stand If operating on muddy or dusty roads, clean and lubricate at shorter intervals. CABLES AND HAND LEVERS For throttle cables, see 1.12 THROTTLE CABLES. Use HARLEY® LUBE for clutch lever and cable Use G40M BRAKE GREASE on front brake lever pin pivot hole and on the end of piston that contacts brake lever. JIFFY STAND _ Clean and lubricate the jy stand. For more information, see 2.35 JIFFY STAND. 2016 Dyna Service: Maintenance 1-35BRAKES 1.14 FLUID INSPECTION WOTES Front brake: Position motoreyele and handlebar so the ‘master cylinder reservoir is level. + Rear brake: Position motorcycle so the master cylinder reservoirs level, AIIABS equippsd models except FLD have a remote brake fluid reservor, Akways inspect remote reservoir when present for proper Mud level 1. See Figure 1-29. View reservoir sight glass and verify fluid presence. Sight glass should appear dark i luis present. 2. If sight glass is not dark, check brake system for fuid leaks, Check that brake pads are properly installed and not worn beyond service wear limits. Perform any neces sary repairs. See 1.15 BRAKE PADS AND DISCS. 3. Remove master oylinder reservoir caver (Iront or rear as appropriate) and verify fluid level, if necessary, add DOT 4 BRAKE FLUID to reservoir Replace cover See 2.16 BLEEDING BRAKES, 4. Front brake hand lever and roar brake foot pedal must have a fim fee! when applied. if not, bleed system using only DOT 4 BRAKE FLUID. See 216 BLEEDING BRAKES, 4. Front 2. Rear: non-ABS models and all FLO. |S. Reweasersooai steers Figure 12. Brake Fu Sight GaneWindow 1-36 2016 Dyna Service: Maintenance REAR PEDAL HEIGHT “The rear brake pedal does nat normally require adjustment. If minor pedal height adjustment is desired 41. See Figure 1-30. Brake rod (5) is threaded into pushrod (3) in rear brake master cylinder (1), and locked in place ‘with jamnut (4), Loosen jamout Awarnin When adjusting brake control rod, never allow more than nine threads to be exposed between control rod and jam ‘nut, If more than nine threads are exposed, brake rod can ‘come apart resulting In loss of rear brake, which could ‘cause death or serious injury. (00306c) 2. Hold pushrod flats and turn the pushrod in the direction Which corrects pedal height. When correct pedal height is obtained, tighten jamnult, 3. Verify that water drain hole in rubber boot (2) faces downward, NOTE Brake pedal free play is built into master cylinder and no adjustment is required. When pedal is pushed down with hand, {a small amount of free play must be felt. Rear brake master cylinder Rubber boot Pushrod Jamaut Brake rod Figure 1-20. R Brake Pedal Height (Typical) INSPECT BRAKE LINES Inspect brake lines for leaks, contact or abrasion. Refer 10 Table 1-14.