Harley Davidson Sportster Models 2009. Service Repair Manual - page 2

Engine Uses Too Much Oil Or Smokes Excessively...1-91
Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc.............................................................................1-91
Low Oil Pressure.......................................................1-91
High Oil Pressure......................................................1-92

Electrical System..............................................................1-92

Alternator Does Not Charge......................................1-92
Alternator Charge Rate Is Below Normal..................1-92
Speedometer Operates Erratically............................1-92

Transmission.....................................................................1-92

Shifts Hard................................................................1-92
Jumps Out Of Gear...................................................1-92
Clutch Slips...............................................................1-92
Clutch Drags Or Does Not Release..........................1-92
Clutch Chatters..........................................................1-92

Handling...........................................................................1-92
Brakes..............................................................................1-92

Brake Does Not Hold Normally.................................1-92

CHASSIS

2.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................2-1

2.2 SPECIFICATIONS

Sportster Specifications......................................................2-8

Chassis Specifications................................................2-8
Tire Specifications.......................................................2-9

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

Vehicle Identification Number (V.I.N.): Sportster Models...2-11

General......................................................................2-11
Abbreviated V.I.N.......................................................2-11

2.4 WHEELS

General.............................................................................2-13
Troubleshooting................................................................2-13
Front Wheel......................................................................2-14

Removal....................................................................2-14
Disassembly: Cast Front Wheel................................2-15
Disassembly: Laced Front Wheel..............................2-15
Cleaning and Inspection............................................2-15
Assembly: Cast Front Wheel.....................................2-15
Assembly: Laced Front Wheel...................................2-16
Installation.................................................................2-20

Rear Wheel.......................................................................2-20

Removal....................................................................2-20
Disassembly..............................................................2-21
Cleaning and Inspection............................................2-21
Assembly...................................................................2-21
Installation.................................................................2-24

Sealed Wheel Bearings....................................................2-24

Inspection..................................................................2-24
Removal....................................................................2-25
Installation.................................................................2-27

2.5 WHEEL LACING: 16 INCH RIM

General.............................................................................2-28
Procedure.........................................................................2-28

2.6 WHEEL LACING: 19 INCH RIM

Procedure.........................................................................2-31

2.7 WHEEL LACING: 21 INCH RIM

General.............................................................................2-35
Procedure.........................................................................2-35

2.8 TRUING LACED WHEELS

General.............................................................................2-39
Lateral Truing....................................................................2-39
Radial Truing.....................................................................2-40

2.9 CHECKING CAST WHEEL RUNOUT

General.............................................................................2-42
Lateral Runout..................................................................2-42
Radial Runout...................................................................2-42

2.10 FRONT BRAKE MASTER CYLINDER

General.............................................................................2-43
Inspection.........................................................................2-43
Removal...........................................................................2-43
Disassembly.....................................................................2-45
Cleaning, Inspection and Repair......................................2-47
Assembly..........................................................................2-47
Installation........................................................................2-48

2.11 FRONT BRAKE CALIPER: XL MODELS

Removal...........................................................................2-52
Disassembly.....................................................................2-53
Cleaning, Inspection and Repair......................................2-55
Assembly..........................................................................2-56
Lubricating Front Caliper Bolt Pins and Boots..................2-56
Installing Brake Pads in Caliper........................................2-57
Installation........................................................................2-58

2.12 FRONT BRAKE CALIPER: XR MODELS

Removal...........................................................................2-60
Disassembly.....................................................................2-61
Cleaning, Inspection and Repair......................................2-62
Assembly..........................................................................2-63
Installation........................................................................2-64

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS

General.............................................................................2-65
Inspection.........................................................................2-65
Removal...........................................................................2-65
Disassembly.....................................................................2-68
Cleaning, Inspection and Repair......................................2-69
Assembly..........................................................................2-70
Installation........................................................................2-72

2.14 REAR BRAKE MASTER CYLINDER: XR
MODELS

General.............................................................................2-73
Inspection.........................................................................2-73
Removal...........................................................................2-73
Disassembly.....................................................................2-74
Cleaning, Inspection and Repair......................................2-75
Assembly..........................................................................2-76

TABLE OF CONTENTS  V

TABLE OF CONTENTS

Installation........................................................................2-77

2.15 REAR BRAKE MASTER CYLINDER
RESERVOIR

General.............................................................................2-79
Removal: XL Models.........................................................2-79
Installation: XL Models.....................................................2-80
Removal: XR Models........................................................2-80
Installation: XR Models.....................................................2-81

2.16 REAR BRAKE CALIPER: XL MODELS

Removal...........................................................................2-82
Disassembly.....................................................................2-84
Cleaning, Inspection and Repair......................................2-85
Lubricating Rear Caliper Bolt Pins and Boots..................2-85
Assembly..........................................................................2-86
Installation........................................................................2-87

2.17 REAR BRAKE CALIPER: XR MODELS

Removal...........................................................................2-90
Disassembly.....................................................................2-91
Cleaning, Inspection and Repair......................................2-93
Assembly..........................................................................2-93
Installation........................................................................2-94

2.18 BRAKE LINES

Front Brake Line: All Models.............................................2-97

Removal....................................................................2-97
Installation.................................................................2-98

Rear Brake Line: XL Models.............................................2-99

Removal..................................................................2-100
Installation...............................................................2-100

Rear Brake Line: XR Models..........................................2-101

Removal..................................................................2-101
Installation...............................................................2-102

2.19 TIRES

General...........................................................................2-103
Removal.........................................................................2-103
Cleaning, Inspection and Repair....................................2-104
Installation......................................................................2-104

Tube Type Tires.......................................................2-104
Tubeless Tires.........................................................2-105

Checking Tire Runout.....................................................2-105

Lateral Runout.........................................................2-105
Radial Runout.........................................................2-105

Wheel Balancing............................................................2-106

Weights for Laced Wheels.......................................2-106
Weights for Cast Wheels.........................................2-106

2.20 LEFT SIDE COVER

General...........................................................................2-107
Opening Left Side Cover................................................2-107
Closing Left Side Cover..................................................2-108
Removing Left Side Cover..............................................2-108
Installing Left Side Cover................................................2-109

2.21 FRONT FORK: XL MODELS

General...........................................................................2-110
Removal.........................................................................2-110
Disassembly...................................................................2-110

Cleaning, Inspection and Repair....................................2-112
Assembly........................................................................2-112
Installation......................................................................2-113

2.22 FRONT FORK: XR MODELS

General...........................................................................2-115
Removal.........................................................................2-115
Disassembly...................................................................2-115

Left Side..................................................................2-115
Right Side................................................................2-117

Cleaning and Inspection.................................................2-119
Assembly........................................................................2-119

Left Side..................................................................2-119
Right Side................................................................2-122

Installation......................................................................2-124

2.23 FORK STEM AND BRACKET
ASSEMBLY

Removal and Disassembly.............................................2-126
Cleaning, Inspection and Repair....................................2-126
Assembly and Installation...............................................2-127

2.24 BELT GUARD AND DEBRIS
DEFLECTOR

Belt Guard: XL Models...................................................2-128

Removal..................................................................2-128
Installation...............................................................2-128

Debris Deflector: XL Models...........................................2-128

Removal..................................................................2-128
Installation...............................................................2-128

Belt Guard: XR Models...................................................2-128

Removal..................................................................2-128
Installation...............................................................2-128

Debris Deflector: XR Models..........................................2-129

Removal..................................................................2-129
Installation...............................................................2-129

2.25 REAR FORK

General...........................................................................2-130
Removal.........................................................................2-130
Disassembly...................................................................2-130
Cleaning and Inspection.................................................2-131
Assembly........................................................................2-131
Installation......................................................................2-131

2.26 SHOCK ABSORBERS

General...........................................................................2-133
Removal.........................................................................2-133
Cleaning and Inspection.................................................2-133
Installation......................................................................2-133

2.27 STABILIZER LINKS

General...........................................................................2-135
Upper Front Stabilizer Link.............................................2-135

Removal..................................................................2-135
Installation...............................................................2-135

Lower Front Stabilizer Link.............................................2-135

Removal..................................................................2-135
Installation...............................................................2-135

Rear Stabilizer Link........................................................2-136

Removal..................................................................2-136

VI TABLE OF CONTENTS

TABLE OF CONTENTS

Installation...............................................................2-136

2.28 FRONT ENGINE MOUNT/ISOLATOR

Removal.........................................................................2-137
Installation......................................................................2-138

2.29 REAR ENGINE MOUNT/ISOLATOR

Removal.........................................................................2-139
Installation......................................................................2-141

2.30 THROTTLE CABLES: ALL MODELS

Removal and Disassembly.............................................2-142
Cleaning, Inspection and Repair....................................2-144
Assembly and Installation...............................................2-144

2.31 CLUTCH CONTROL

General...........................................................................2-146
Removal and Disassembly.............................................2-146

Clutch Cable: Lower................................................2-146
Clutch Lever and Clutch Cable: Upper....................2-147
Clutch Hand Control................................................2-147

Assembly and Installation...............................................2-148

Clutch Hand Control................................................2-148
Clutch Lever and Clutch Cable: Upper....................2-149
Clutch Cable: Lower................................................2-149
Finish.......................................................................2-149

2.32 HANDLEBARS

Removal.........................................................................2-150

All Models................................................................2-150
XL 883C and XL 1200C..........................................2-150
All XL Models Except XL 883C, XL 1200C.............2-151
XR1200...................................................................2-152

Installation......................................................................2-153

XL 883C and XL 1200C..........................................2-153
All XL Models Except XL 883C, XL 1200C.............2-154
XR1200...................................................................2-154
All Models................................................................2-155

2.33 FRONT FENDER

XL Models......................................................................2-156

Removal..................................................................2-156
Installation...............................................................2-156

XR Models......................................................................2-156

Removal..................................................................2-156
Installation...............................................................2-156

2.34 REAR FENDER: ALL XL MODELS
EXCEPT XL 1200N

General...........................................................................2-157
Removal.........................................................................2-157
Installation......................................................................2-159

2.35 REAR FENDER AND LICENSE PLATE
BRACKET: XL 1200N

General...........................................................................2-161
Removal and Disassembly.............................................2-161
Assembly and Installation...............................................2-163

2.36 REAR FENDER: XR MODELS

Removal.........................................................................2-166
Installation......................................................................2-166

2.37 JIFFY STAND

General...........................................................................2-167
Jiffy Stand Interlock: International Models......................2-167
Removal.........................................................................2-167
Cleaning and Lubrication................................................2-167
Installation......................................................................2-168

2.38 SEAT: XL MODELS

General...........................................................................2-169
Seat Removal: XL Models..............................................2-169
Seat Installation: XL Models...........................................2-169

2.39 SEAT: XR MODELS

Seat Removal: XR 1200 Model......................................2-171
Seat Installation: XR 1200 Model...................................2-171
Passenger Pillion: XR 1200 Model.................................2-171

Removal..................................................................2-171
Installation...............................................................2-171

2.40 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS

Right Footrest and Rear Brake Pedal Assembly............2-173

Removal..................................................................2-173
Installation...............................................................2-173

Left Footrest and Shift Lever Assembly..........................2-173

Removal..................................................................2-173
Installation...............................................................2-173

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS

Right Footrest and Rear Brake Pedal Assembly............2-175

Removal..................................................................2-175
Installation...............................................................2-175

Left Footrest and Shift Lever Assembly..........................2-176

Removal..................................................................2-176
Installation...............................................................2-177

Adjusting Shift Pedal......................................................2-178

2.42 RIDER FOOT CONTROLS: XR MODELS

Right Footrest and Rear Brake Pedal Assembly............2-179

Removal..................................................................2-179
Installation...............................................................2-179

Left Footrest and Shift Lever Assembly..........................2-179

Removal..................................................................2-179
Installation...............................................................2-180

Adjusting Shift Pedal......................................................2-180

2.43 PASSENGER FOOTRESTS

General...........................................................................2-181
XL Models......................................................................2-181

Removal..................................................................2-181
Installation...............................................................2-181

XR Models......................................................................2-181

Removal..................................................................2-181
Installation...............................................................2-181

TABLE OF CONTENTS  VII

TABLE OF CONTENTS

2.44 FORK LOCK

Removal.........................................................................2-183
Installation......................................................................2-183

ENGINE

3.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................3-1

3.2 SPECIFICATIONS

Specifications: 2009 Sportster Models...............................3-5

3.3 ENGINE

General.............................................................................3-11

3.4 OIL PRESSURE

General.............................................................................3-12

Oil Pressure Indicator Lamp......................................3-12

Checking Oil Pressure......................................................3-13

Connecting Gauge: XL Models.................................3-13
Connecting Gauge: XR Models.................................3-13
Testing Pressure........................................................3-13
Removing Gauge: XL Models....................................3-13
Removing Gauge: XR Models...................................3-13
Finalize Test...............................................................3-13

3.5 CRANKCASE BREATHING SYSTEM: XL
MODELS

General.............................................................................3-15

3.6 CRANKCASE BREATHING SYSTEM: XR
MODELS

General.............................................................................3-16

3.7 TROUBLESHOOTING

Diagnosing Valve Train Noise...........................................3-18
Compression Test.............................................................3-18
Cylinder Leakage Test......................................................3-18
Diagnosing Smoking Engine or High Oil Consumption.....3-19

Check Prior to Cylinder Head Removal.....................3-19
Check After Cylinder Head Removal.........................3-19

Adjustment and Testing....................................................3-19

General......................................................................3-19

3.8 ENGINE LUBRICATION SYSTEM

Oil Pump Operation..........................................................3-20
Oil Flow: XL Models..........................................................3-23
Oil Flow: XR Models.........................................................3-23

3.9 HOW TO USE THIS SECTION

Typical Symptoms.............................................................3-29
Top End Repair.................................................................3-29
Bottom End Repair...........................................................3-29

3.10 TOP END SERVICE

Engine in Chassis.............................................................3-30
Engine Removed from Chassis........................................3-31

3.11 BOTTOM END SERVICE

Engine in Chassis.............................................................3-32
Engine Removed From Chassis.......................................3-33

3.12 REMOVING ENGINE FROM CHASSIS

General.............................................................................3-34
Procedure: XL Models......................................................3-34
Procedure: XR Models.....................................................3-38

3.13 INSTALLING ENGINE IN CHASSIS

General.............................................................................3-43
Procedure: XL Models......................................................3-43
Procedure: XR Models.....................................................3-45

3.14 PRECISION COOLING SYSTEM: XR
MODELS

General.............................................................................3-48
Return Oil Manifold...........................................................3-48

Removal....................................................................3-48
Installation.................................................................3-49

Cylinder Head Oil Return Lines........................................3-49

Removal....................................................................3-49
Installation.................................................................3-50

Cylinder Head Oil Feed Assembly....................................3-50

Removal....................................................................3-50
Installation.................................................................3-50

Oil Pump Lines.................................................................3-51

Removal....................................................................3-51
Installation.................................................................3-52

Oil Cooler.........................................................................3-52

Removal....................................................................3-52
Installation.................................................................3-52

3.15 TOP END OVERHAUL: DISASSEMBLY

General.............................................................................3-53
Stripping Motorcycle for Top End Repair..........................3-53
Cylinder Heads.................................................................3-54

Disassembling Rocker Covers..................................3-54
Removing Cylinder Head..........................................3-56
Disassembling Push Rods and Covers.....................3-59

Cylinder and Piston..........................................................3-60

3.16 TOP END OVERHAUL: ASSEMBLY

General.............................................................................3-62
Piston and Cylinder..........................................................3-62
Push Rods, Covers, and Retainers..................................3-63
Cylinder Head...................................................................3-65
Rocker Covers..................................................................3-68
Assembling Motorcycle After Top End Repair..................3-71

3.17 BOTTOM END OVERHAUL:
DISASSEMBLY

General.............................................................................3-73
Tappets.............................................................................3-73
Oil Pump: XL Models........................................................3-73
Gearcase Cover and Cam Gears: XL Models..................3-73
Oil Pump Housing/Gearcase Cover and Cam Gears: XR
Models..............................................................................3-74
Crankcase........................................................................3-76

Removing Piston Oil Jets..........................................3-77

VIII TABLE OF CONTENTS

TABLE OF CONTENTS

5.

Lubricate the following parts prior to assembly using a
light coat of KS62F assembly grease from the service
parts kit. All other surfaces must be dry for assembly.

a.

Nose radius of piston.

b.

All surfaces of piston seal and dust seal.

NOTE

A damaged piston bore will leak when reassembled. Do not
use metal objects to remove or install components in piston
bore. Prevent damage to bore by only using a wooden toothpick
when servicing caliper.

6.

See 

Figure 2-141

. Install a new piston seal (3) and a new

dust seal (2) into piston bore.

7.

Carefully insert piston by hand, nose radius first, into cal-
iper bore. If installation shows resistance, remove piston
and check that seals are properly installed and fully seated
in grooves.

8.

Install bleeder valve if removed. Do not tighten bleeder
valve at this time.

1

2

3

sm05122

1.

Pad spring

2.

Bushing

3.

Boot

Figure 2-140. Assemble Caliper

3

2

1

sm05115

1.

Wooden toothpick

2.

Dust seal

3.

Piston seal

Figure 2-141. Caliper Seals

INSTALLATION

1.

See 

Figure 2-142

. If removed, install bolt pin boot (1).

2.

Apply approximately 0.4 g of G40M BRAKE GREASE
inside bolt pin boot.

3.

If removed, install wear plate (2) on mounting bracket.

4.

See 

Figure 2-143

. Apply a drop of LOCTITE 272 Thread

Lock to threads of bolt pin (6).

5.

Place rear caliper assembly onto mounting bracket. Install
bolt pin (6), being careful not to pinch or roll boot over.
Tighten bolt pin to 14-18 ft-lbs (19.6-24.5 Nm). See

Figure 2-144

. Ensure lip of boot (1) properly engages the

groove (2) in the bolt pin.

6.

See 

Figure 2-143

. Install mounting bolt (5) and tighten to

14-18 ft-lbs (19.6-24.5 Nm).

NOTE

Brake caliper housing has a positive stop for banjo fitting. When
tightening banjo bolt into brake caliper in the next step, rotate
banjo fitting clockwise until it contacts positive stop.

7.

Position a new washer (3) on each side of hydraulic brake
line (1) banjo fitting. Insert banjo bolt (2) through washers
and fitting and thread bolt into caliper housing. Tighten to
20-25 ft-lbs (27.1-33.9 Nm).

8.

Install brake pads. See 

1.10 BRAKE PADS AND DISCS:

XR MODELS, Brake Pad Replacement: Rear

.

9.

Secure lower end of shock absorber to rear fork. Tighten
to 30-45 ft-lbs (40.7-61.0 Nm)

10. Adjust drive belt and check vehicle alignment. See

1.16 REAR BELT DEFLECTION

.

HOME

2-94  2009 Sportster Service: Chassis

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

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTES

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.

11. Remove rear brake master cylinder reservoir cap. Add

HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID to reservoir
until fluid reaches upper fluid level (3). Do not overfill
reservoir. Do not reuse brake fluid.

12. Bleed brake system. See 

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

.

A plugged or covered relief port can cause brake drag or
lock-up, which could lead to loss of control, resulting in
death or serious injury. (00288a)

13. Verify proper operation of master cylinder relief port.

a.

Press against rear brake caliper to push caliper piston
back into its bore. This pushes brake fluid back
through master cylinder and verifies that relief port is
not plugged.

b.

Pump brake pedal until caliper piston pushes pads
against disc and pressure is returned to brake system.

14. Add HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID to

reservoir until fluid reaches upper fluid level.

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

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

15. Test brake system.

a.

Turn ignition switch ON. Pump brake pedal to verify
operation of brake lamp.

b.

Test ride motorcycle at low speed. If brakes feel
spongy, bleed system again. See 

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

.

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

1

2

sm05120

1.

Bolt pin boot

2.

Wear plate

Figure 2-142. Caliper Mount

1

6

2

3

4

5

sm05109

1.

Rear brake line

2.

Banjo bolt

3.

Washer (2)

4.

Bleeder valve

5.

Mounting bolt

6.

Bolt pin

Figure 2-143. Rear Caliper Assembly

HOME

2009 Sportster Service: Chassis  2-95

1

2

sm05123

1.

Boot

2.

Bolt pin groove

Figure 2-144. Bolt Pin and Boot

HOME

2-96  2009 Sportster Service: Chassis