2009 MY Technical Changes

2009 MY
Technical Changes
Harley-Davidson® & Buell® Motorcycles
© 2008 by HD all right reserved
Big Twin Powertrain Overview
Transmission top cover – New vent line
Left side flywheel – Shallower counter bore
Touring oil pan – New baffling for oil routing
Touring exhaust bracket – Attached on to the transmission case for cross
under exhaust.
Touring oil dipstick - now has marking for both 2 & 3 wheeled vehicles.
Exhaust gasket – New gasket at cylinder head
Clutch cable – Smaller cable diameter to help reduce lever effort
Touring CPS – New mounting on frame
Cam cover – Removal of ribs
Stator plug change – Material change for the plug that gets pulled through
the case.
Increased flywheel end play specification to .003”-.013” or .07 - .37mm
Twin Cam Powertrain Changes
New Torca Clamp P.N. 65296-95A
New coating on the fastener to
reduce friction during assembly,
then acts like a secondary locking
mechanism. Torque to 38-43 ft/lbs
or 51.5 – 58.3 Nm
New Vent Line
P.N.62372-09
New Exhaust Port Gasket
P.N. 65324-83B
Change to ALL Flywheels
Securing
Segments
Lock Ring
Lock rings on ALL transmissions
Now has serrations on one face.
Smooth surface of lock ring must face the
gear.
END PLAY SPECIFICATION
.003” - .013”
Starting in 09MY the flywheel will be able to
use either the long or short bolt. Long bolts will
be used up in production before the short bolt
becomes common for both. New flywheels will
retrofit.
CVO™ Model Continuous
Improvement Changes
Lower rocker box – Relieved for spring retainer clearance
This eliminates noise due to spring retainer contacting the
rocker box.
Rocker box gasket – Matches the rocker box
Do not use the old gasket with the new rocker box lower
Cylinder base gasket – New quad ring & drain down O-ring
Eliminates cylinder base seal leaking
New seal is orange
Drain down O-ring is smaller and orange
Do not mix new quad seal with old O-ring
New O-Ring for center bolt
Eliminates leaking at the center case bolt.
Review TT 372 and 370 for additional specifics on these updates.
Product Programs will be offered to update in service powertrains.
Model
Year2009
2009 Touring Family
Service Procedures
Service Parts
No Powertrain to Frame alignment.
Tour Pak® carrier shipped in the rearward
riding position. Owner can move if desired.
AM/FM antenna will retro back to 1998, the CB will
require removal of loading coil in Tour Pak® carrier.
CB antenna will be marked for identification.
Mid Frame Air Deflectors installed at PDI on
Ultra Classic® , Police and CVO™ Ultra
Classic® models.
ROAD KING® CLASSIC Model - FLHRC
2009 model 16” front tire tread and construction
unique. No to be used on earlier models because
it will not match rear tread pattern. New tire will
also not match older rear tire treads and must not
be used.
New Dunlop® tires on all touring models
Model Specific - no retrofitting forward or back
Engine Idle Temperature Management System
is now rider controlled.
The 2009 calibration for the EITMS (Engine
Idle Temperature Management System) can
NOT be used on 2008 MY FL’s.
New wheel lacing procedure on spoke rear
wheels.
New oil pan is used on all FL’s.
New 68 tooth rear sprocket on all models
New 140 tooth rear belt
Oil cooler and mount on CVO™ and Police models.
Service Specifications
Rear belt adjustment- On jiffy stand or jack
FLHX – ¼ to 5/16 or 6.35 - 8.0mm
All Others - 10.7 ounces 125mm
All others ¼ to 7/16 or 6.35 – 11.0mm
Fork oil – Road King® models - 11.0 ounces 125mm
Fork stem nut - 70 to 80 ft/lbs 94.9 – 108.5
Nm
Steering head bearing adjustment
Stops 3rd or 4th swing
Front tire pressure
All models – 36 psi
Rear tire pressure
All models 40 psi
Use current tail lamp and turn signals
Revised light bars
New license plate mounting
Rear tip light now LED
Redesigned routing using a
2-1-2 design
Better sealing joints
Catalyst in center section
Active exhaust used on HDI
Exhaust
• Saddlebags move back .5”
• New support structures/guards
• Rated payload increased by 5 lbs.
Saddlebags
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Rear Lighting
• Uses current Tour Pak®
• New support structure
• Rated payload increased
by 5 lbs.
Tour Pak® carrier
•
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•
•
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•
180/65/16 rear tire
New 28 spoke style wheel
5” wide rear wheel
~ 1/2” longer wheelbase
Redesigned wider fender
New 68 tooth compensated rear sprocket
New 140 tooth rear belt
Rear Wheel, Tire, Fender
Shorter antennas
for all radio and CB
models. No SWR
adjustment for CB.
Antennas
Restyled cast wheels
17” front wheel
(except FLHRC which is
still 16” for wide white wall)
New tire construction
Front Wheel
New triple tree
No lock washer on steering stem
New torque on fork stem nut
Frame rake increased to 26 degrees
Fork angle 29.5 degrees – 6.69” trail
(except FLHR/FLHRC)
Use a damper valve
Front Forks
Completely redesigned frame
2 piece bolt-together construction
Majority robotically welded
New 4 point engine mount system
Removable rear frame section
Frame & Mounts
• Mid frame heat deflectors stock on
Ultra, Police and CVO Ultra models.
(dealer installed at PDI)
• New heat management calibration
(rider enable/disable)
Rider Comfort
New longer crate used to ship vehicle which enables Tour Pak® carrier to be
installed at factory in the most rearward position. (not shipping position as in past)
Crate
• Conventional damping design
• No lock washer on steering stem
• New torque on stem nut
Front Forks
•
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•
•
•
•
•
•
•
180/65/16 rear tire
5” wide rear wheel
~ 1/2” longer wheelbase
Redesigned wider fender
New 68 tooth compensated rear sprocket
Rear Wheel, Tire, Fender
No left side head pipe on rear cylinder
Right to left crossover under swingarm
Mounting point to transmission case in rear – DO NOT use longer bolts
New oil pan new for 2009 on all FL’s – change to baffles inside
HDI models will use active exhaust system
Exhaust System
• Front and rear tires new for 2009
• Front and rear are 16 inch
DO NOT USE 2009 TIRES ON PREVIOUS YEARS
DO NOT USE PREVIOUS YEAR TIRES ON 2009
FLHRC (only applies to Road King® Classic models)
New Powertrain Mounting
Front: Left fixed
Right removable
Rear: Left removable
Right fixed
Steering Stops
A – Tube sections
B – Formed plate
C – Cast sections
C
C
B
A
A
C
C
Note that the baffle cover is not removable
Oil enters above metal plate, flows to rear and down into lower baffles. Large hole is for dipstick.
Oil flows forward around walls to pickup in front of pan.
Mounting points for the exhaust cross over
support bracket. These are blind holes,
do not use longer bolts.
2009 VRSC Family
TM
VRSC Model Review
™
Service Procedures
The steering stem nut has been changed to a
bolt on all VRSCTM models. A new fall away
procedure will be used.
Exhaust system mounting
1. Cross over clamp. Fully seat the crossover
connection and torque clamp to 13-15 Nm.
2. Exhaust port flanges. Tighten the port nuts to
8-12 Nm.
3. Muffler stud plates. Torque the flange nuts to
18-27 Nm.
4. Muffler inlet Torca clamps. Orient clamps and
torque to 51.5-58.3 Nm.
Service Parts
There are two modules for the LED lamps.
The TSSM/HSSM under the seat for basic
functions.
The front module controls the LED function
between running light and turn signal operation.
• New fender
• New inverted forks
• New front wheel
• ABS optional
FRONT WHEEL
• Integrated LED Lights
Tail Light
Stop Light
Turn Signals
• Side mounted plate
(Domestic model only)
• 18’ 240mm rear tire
ENGINE
EXHAUST SYSTEM
• Floating rear disc
• Pewter engine paint
• Satin chrome
• 1250cc
• Extended coverage shields
• 122 hp/85 ft/lbs
• HDI / Japan models have catalysts in both head pipes
• New cylinder head exhaust port machining
• All mufflers except Japan are the same
• New dip stick location
REAR WHEEL
LED TURN SIGNALS
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•
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• New air cleaner cover shape
• New side air intakes
• New radiator side covers
• New wide rear fender
• New seat
• All body panels are now
formed composite
New triple clamp
Internal wiring
New gauge graphics
New gauge housing
Satin chrome headlight mount
Satin black headlight bucket
RIDER CONTROLS
BODY PANELS
2009 VRSCF – Content Overview
e
scl
Mu
A
DX
VRSC
D
SC
VR
SC
VR
Exhaust heat shields
TDC
mark
Keyway
For 2009MY the cases on all VRSC™ models will not have the threaded hole for using
the crankshaft locking pin (HD 45306).
The alternator cover will now have a TDC mark that will align with the keyway on the
crankshaft. This will be used to position the crankshaft when timing the cam drive components.
Technicians should apply a paint mark during the first valve service to make identifying
the crank position easier during future services.
®
Buell 2009 Model Review
Service Procedures
Service Parts
New Clutch adjustment procedure and specification on Ulysses® models due to change
in the cable guide. Cable is removed from
the guide on the handle bar for adjustment.
New tire option on Firebolt® models
New belt on XB models
1125CRTM model uses a longer rear belt
1125 models - new rotor and stator
Police lighting kits are ordered separately
from bikes based on lighting configuration.
Service Specifications
New clutch cable free play specification on
Ulysses® models.
.140” to .180”
3.55 to 4.57mm
NEW: 76/27 final
drive gearing for
hard acceleration
with lengthened
swingarm. (+5mm)
Threaded mounting points for rear
stand supports.
NEW: Red highlights
on front brake caliper,
wheels and rear shock
spring
NEW: Racing Red &
Midnight Black bodywork
NEW: Black fork legs,
handlebar clamps,
frame, swingarm, heel
guards and brake &
clutch levers
NEW: Minimalist
headlight and
fly screen
NEW: Black anodized,
tapered aluminum
clubman-style handlebar
2009 1125CR™ Model – Content Overview
Improved turn signal /
mirror mount pivots
Gear position readout
added to all 1125
models
instrument clusters
New handle bars
New top clamp
Pre-wired for heated grips
New ignition key
location
®
XB12XP Ulysses Police Model
DESCRIPTION
Standard Ulysses® platform with police specific
wire harness capable of allowing a dealer or up-fitter
quick installation of options for police, forestry and
government agencies.
Police kit is dealer installed to agency specification
Lighting kits available with color options and position
options
Technical Specifications:
• Fuel in the frame – 4.4 gallon
• ZTL™ front brake system
• Top and side cases
• Pirelli® Scorpion® Sync tires
• Siren and light package
LED front, side, rear
• Additional auxiliary wire harness
(uses rear accessory connector)
• Tall windscreen
• 22.5 degree head angle / 54.5” wheelbase
• Adjustable backrest/tail rack
• Heated grips
• Hand deflectors with LEDs
• Narrow junior bags
2009 Softail Family
®
®
Softail Model Review
Service Procedures
Service Parts
New tire direction on FXCW models
New negative battery cable mounting point
on all models except FXCW/C
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Service Specifications
Tire pressures Refer to chart in this document
New rear shocks
New exhaust clamps and mounts
New front brake line on FLSTC
New handle bars, risers and top clamp FLSTC
New HDI fog lamps
New jiffy stand sensor
New ECM with improved IAC valve software
(running change in January 08)
• New main wire harness – ignition connectors
changed
• New negative battery cable
• New FXCW spark plug wires
• New front fender on FXST, FXSTC, FXSTCB
• Longer fender strut acorn nut on FXSTSB
(running change in 08)
• Extra cutout on FLSTC/N rear fender for wire
clearance.
(running change in 08)
Softail Model specific– Technical changes
®
All Models
New exhaust Torca® clamps
Common exhaust mounting studs – frame to support tube
New main wiring harness – retro as a complete assembly
New negative battery cable – new ends – retro to ‘08
New common ECM
New jiffy stand sensor
FXCW Softail® Rocker™ model
FXCWC Softail® Rocker™ Custom model
FXSTB Softail® Night Train® model
FXSTC Softail® Custom model
•New
•New
•New
•New
low profile front fender
tire tread direction
rear shocks and bumpers
seat post/grommet design
•New low profile front fender
•New
•New
•New
•New
low profile front fender•
tire tread direction
rear shocks and bumpers
seat post/grommet design
•New low profile front fender
FLSTN Softail® Deluxe model
•New seat with “collapsing” sides
FLSTSB Softail® Cross Bones™ model
• No new technical content
FLSTF Softail® Fat Boy® model
•No new technical content
FLSTN seat detail
Tire Direction on FXCW/C
viewed from front of the tire
2008
2009
Seats will have a new
post with a spherical end to accept the
new seat grommets
Collapsible pockets in
filler relieve pressure in the
inner thigh contact area
Front End changes
Rider/Passenger Comfort
• New 1940’s style leather saddle bags with
quick opening buckles
• New passenger pillion shape
• New passenger backrest – shape and angle
FLSTC
Heritage Softail® Classic
New Cross-Bones™ style
handlebars with FXSTC risers.
New “Cats-Eye” instrument
console (domestic only)
Two tone leather tank panel
New king-size detachable
windshield
New chrome windshield brackets
New chrome headlight nacelle
New HDI passing lamps – same
style as headlight
Front Wheel
Optional white walls on chrome profile laced wheels
New “old-school” stainless steel floorboards and brake pedal
New chrome lower trim and name script plate on front fender
2009 Dyna Family
®
DYNA® Model – Content Overview
All Models:
New fuel tank sender with range readout on speedometer
New silver faced gauges
FXDF Fat Bob®
FXD, FXDC, FXDL
Service Parts
Service Procedures
New rear shocks – same as CVO® Fat Bob® model
No new service parts
No new technical content
No new service procedures
Service Specifications
FXDB Street Bob Model– Content
Black wrinkle fuel tank console
Chopped straight cut exhaust mufflers
Street Bob® air cleaner insert
Silver speedometer face with fuel range readout
Internally wired handlebars
Gloss black wheel rims (anodized optional)
New LED – “retro” styled tail light
New bobbed rear fender
No fender support covers
New integrated LED stop/tail/turn signals
Red DOM – Amber HDI
Black wrinkle belt guard
Black wrinkle battery cover
New lower solo seat (25.8”)
Black and silver with non-highlighted fins
(Japan market bikes will have highlighted fins)
Mid mounted controls
Powertrain
FRONT
REAR
®
2009 Sportster Family
®
Sportster® Model - Content
All Sportster® Models:
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Change to low fuel light - Requires both power and road speed inputs to go out.
New front fender - Reduced gap between tire and fender.
New rear spring and dampening rates - (except 1200N and 883L)
New frame- Jiffy stand bracket change
2008
2009
883C
New stabilizer links
Suspension upgrade - All models except 1200N & 883L
New custom disc rear wheel
883C and 1200C
4 pound weight reduction
1200C
Lowered fender - All Models
Service Procedures
Primary fluid level does NOT need to be inspected at PDI.
RUNNING CHANGES
New primary chain inspection cover and gasket can only be used as a set. (Tech Tip 377)
Cover
34745-04
Gasket
34986-04
Cover
35000-08
Gasket
34990-08
Low fuel light will only go out after refueling when road speed indication received.
Battery tray and left side cover changed.
New parts being introduced at start of MY
38698-04C
38741-05C
65324-83B
34014-06A
30046-08
27773-07
27694-07
37107-06
Clutch Cable 883, 883R ,883C, 1200C, 1200R
Clutch Cable 883L, 1200L, 1200N
Exhaust Port Gasket-All XL/XR Models
Shifter Mechanism -All XL/XR Models
Stator Assembly w/Black Connector-All XL/XR Models
EFI Module, E-Coat Throttle Bracket and Fastener
EFI Module, E-Coat Throttle Bracket and Fastener
Shifter Shaft Seal
New parts introduced as running changes during 2008 MY
35030-89A Mainshaft Bearing-All XL/XR Models
17362-07A Rocker Inner Gasket-All XL Models
17695-07A Chimney Gasket-All XL Models
17501-04 rev C
Rocker Cover, Top Polished
17551-04 rev D
Rocker Cover, Top Chromed
17655-04 rev C
Rocker Cover, Top Black
34990-08
Inspection Cover Gasket
34997-08
Inspection Cover