Harley Davidson Sportster Models 2009. Service Repair Manual - page 9

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

4.7 FUEL TANK: XR MODELS, Assemble Fuel
Tank

4.5-5.1 Nm

40-45 in-lbs

Filler housing screws

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

61.0-67.8 Nm

45-50 ft-lbs

Footrest bracket fastener

2.42 RIDER FOOT CONTROLS: XR MODELS, Left
Footrest and Shift Lever Assembly

61.0-67.8 Nm

45-50 ft-lbs

Footrest bracket fastener: XR models

2.43 PASSENGER FOOTRESTS, XR Models

61-68 Nm)

45-50 ft-lbs

Footrest bracket screw (XR)

2.42 RIDER FOOT CONTROLS: XR
MODELS, Right Footrest and Rear Brake Pedal
Assembly

27.1-32.5 Nm

20-24 ft-lbs

Footrest clevis fastener: XR models

2.42 RIDER FOOT CONTROLS: XR MODELS, Left
Footrest and Shift Lever Assembly

27.1-32.5 Nm

20-24 ft-lbs

Footrest clevis fastener: XR models

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

61.0-67.8 Nm

45-50 ft-lb

Footrest mount fastener

1.13 CLUTCH, Adjustment

61.0-67.8 Nm

45-50 ft-lb

Footrest mount fastener: XR models

1.14 TRANSMISSION LUBRICANT, Transmission
Lubrication: Sportster Models

61.0-67.8 Nm

45-50 ft-lb

Footrest mount fastener: XR models

2.42 RIDER FOOT CONTROLS: XR
MODELS, Right Footrest and Rear Brake Pedal
Assembly

8.1-12.2 Nm

72-108 in-lbs

Footrest wear peg

2.42 RIDER FOOT CONTROLS: XR MODELS, Left
Footrest and Shift Lever Assembly

8.1-12.2 Nm

72-108 in-lbs

Footrest wear peg

1.22 FRONT FORK OIL, Changing Fork Oil: XR
Models

29-39 Nm

21-29 ft-lbs

Fork cap: XR models

1.22 FRONT FORK OIL, Changing Fork Oil: XR
Models

29-39 Nm

21-29 ft-lbs

Fork cap: XR models

2.22 FRONT FORK: XR MODELS, Assembly

17-22 Nm

150-195 in-lbs

Fork cap: XR models

2.22 FRONT FORK: XR
MODELS, Assembly/Second torque. Tighten to
this torque second.

29-39 Nm

21-29 ft-lbs

Fork cap: XR models

2.22 FRONT FORK: XR MODELS, Assembly

29-39 Nm

21-29 ft-lbs

Fork cap: XR models

1.22 FRONT FORK OIL, Changing Fork Oil: XR
Models

17-22 Nm

150-195 in-lbs

Fork cap to retainer nut: XR models

1.22 FRONT FORK OIL, Changing Fork Oil: XR
Models

17-22 Nm

150-195 in-lbs

Fork cap to retainer nut: XR models

2.22 FRONT FORK: XR MODELS, Assembly

17-22 Nm

150-195 in-lbs

Fork cap to retainer nut: XR models

2.22 FRONT FORK: XR MODELS, Assembly

14.9-24.4 Nm

132-216 in-lbs

Fork cartridge fastener

1.22 FRONT FORK OIL, Changing Fork Oil: XL
Models

29.9-78.7 Nm

22-58 ft-lbs

Fork slider tube cap

1.22 FRONT FORK OIL, Changing Fork Oil: XL
Models

29.9-78.7 Nm

22-58 ft-lbs

Fork slider tube cap

2.21 FRONT FORK: XL MODELS, Assembly

14.9-24.4 Nm

132-216 in-lbs

Fork slider tube fastener

2.23 FORK STEM AND BRACKET
ASSEMBLY, Assembly and Installation

8.1-10.9 Nm

72-96 in-lbs

Fork stem bolt, final

2.23 FORK STEM AND BRACKET
ASSEMBLY, Assembly and Installation

31.2-36.6 Nm

23-27 ft-lbs

Fork stem bolt, initial

1.19 STEERING HEAD BEARINGS, Adjustment

40.7-47.5 Nm

30-35 ft-lbs

Fork stem pinch screw

TORQUE VALUES  XV

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

2.23 FORK STEM AND BRACKET
ASSEMBLY, Assembly and Installation

40.7-47.5 Nm

30-35 ft-lbs

Fork stem pinch screw

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

9.0-13.6 Nm

80-120 in-lbs

Forward and lower sprocket cover
screws: XR models

5.7 DRIVE BELT, Installation

9.0-13.6 Nm

80-120 in-lbs

Forward and lower sprocket cover
screws: XR models

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Return Lines

9.5-12.2 Nm

84-108 in-lbs

Front cylinder oil line retainer nut

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

81.4-95.0 Nm

60-70 ft-lbs

Front engine mount bolt

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

81.4-95.0 Nm

60-70 ft-lbs

Front engine mount bolt

2.33 FRONT FENDER, XL Models

10.9-17.6 Nm

96-156 in-lbs

Front fender (XL) mounting screw

2.33 FRONT FENDER, XR Models

20.4-25.8 Nm

15-19 ft-lbs

Front fender (XR) mounting screw

2.33 FRONT FENDER, XR Models

4.1-6.8 Nm

36-60 in-lbs

Front fender bracket (XR) screw

2.21 FRONT FORK: XL MODELS, Installation

40.7-47.5 Nm

30-35 ft-lbs

Front fork bracket pinch screw

2.22 FRONT FORK: XR MODELS, Installation

40.7-47.5 Nm

30-35 ft-lbs

Front fork bracket pinch screw

1.19 STEERING HEAD BEARINGS, Adjustment

40.7-47.5 Nm

30-35 ft-lbs

Front fork lower bracket pinch screw

1.22 FRONT FORK OIL, Changing Fork Oil: XL
Models

1.5-2.0 Nm

13-17 in-lbs

Front fork oil drain screw

2.21 FRONT FORK: XL MODELS, Installation

29.9-78.7 Nm

22-58 ft-lbs

Front fork slider tube cap

1.10 BRAKE PADS AND DISCS: XR
MODELS, Brake Pad Replacement: Front

1.0-2.0 Nm

9-17 in-lbs

Front master cylinder cover screw

2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation

1.0-2.0 Nm

9-17 in-lbs

Front master cylinder cover screw

1.4 MAINTENANCE SCHEDULE, General

1.0-2.0 Nm

9-17 in-lbs

Front master cylinder reservoir cover
screw

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

61.0-67.8 Nm

45-50 ft-lbs

Front muffler mount-to-frame fastener

4.17 FUEL INJECTORS, Installation

6.8 Nm

60 in-lbs

Fuel hose retaining bracket screw

4.18 FUEL PUMP, Assembly

2.1-4.1 Nm

19-36 in-lbs

Fuel pump/sender harness grounding
screw

4.18 FUEL PUMP, Assembly

2.1-4.1 Nm

19-36 in-lbs

Fuel pump bracket mounting screw

1.4 MAINTENANCE SCHEDULE, General

4.5-5.1 Nm

40-45 in-lbs

Fuel pump module mounting screw

1.29 FUEL SUPPLY FILTER, Installation

4.5-5.1 Nm

40-45 in-lbs

Fuel pump module mounting screw

4.18 FUEL PUMP, Installation

4.5-5.1 Nm

40-45 in-lbs

Fuel pump module mounting screw

4.7 FUEL TANK: XR MODELS, Installing Fuel Tank

2.7-3.4 Nm

24-30 in-lbs

Fuel tank cover fastener

4.7 FUEL TANK: XR MODELS, Installing Fuel Tank

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank front fastener

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

3.16 TOP END OVERHAUL:
ASSEMBLY, Assembling Motorcycle After Top End
Repair

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

4.6 FUEL TANK: XL MODELS, Installing Fuel Tank

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

XVI TORQUE VALUES

1.11

TIRES AND WHEELS

TIRES

Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a Harley-Davidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on
the rim or cause tire failure, which could result in death
or serious injury. (00023a)

Use only Harley-Davidson approved tires. See a Harley-
Davidson dealer. Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)

Use inner tubes on laced (wire spoked) wheels. Using
tubeless tires on laced wheels can cause air leaks, which
could result in death or serious injury. (00025a)

NOTES

•

Inner tubes must not be used in radial tires and radial tires
must not be used on laced (wire spoked) wheels.

•

Tubeless tires are used on all Harley-Davidson cast and
disc wheels.

•

Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.

•

New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the
stack compresses the tires and closes down the beads.

Check tire pressure and tread:

•

As part of the pre-ride inspection.

•

At every scheduled service interval.

1.

Inspect each tire for punctures, cuts and breaks.

2.

Inspect each tire for wear. Replace tires before they reach
the tread wear indicator bars.

NOTE

Missing indicator wear bars represent less than  1/32 in. (0.8
mm) tread pattern depth remaining.

3.

Check for proper front and rear tire pressures when tires
are cold. Compare results against 

Table 1-9

.

Table 1-8. Tire Sizes: 2009 Sportster Models

NUMBER

SIZE

MOUNT

MODEL

D209 120/70 ZR 18

18 in.

front

XR 1200

D209 180/55 ZR 17

17 in.

rear

XR 1200

D401F 100/90-19

19 in.

front

XL 883, XL 883R, XL 883L,
XL 1200R, XL 1200L, XL 1200N

D402F MH90-21

21 in.

front

XL 883C, XL 1200C

D401 150/80B16

16 in.

rear

All XL models

2009 vehicles use Dunlop Harley-Davidson tires only.

Table 1-9. Tire Pressures: 2009 Sportster Models

TIRE PRESSURE (COLD)

MODEL

REAR

FRONT

kPa

PSI

kPa

PSI

248

36

206

30

XL models (solo rider)

275

40

206

30

XL models (rider and passenger)

262

38

248

36

XR models (solo rider)

290

42

248

36

XR 1200 (rider and passenger)

HOME

1-36  2009 Sportster Service: Maintenance

TIRE REPLACEMENT

Inspection

Harley-Davidson tires are equipped with wear bars that
run horizontally across the tread.When wear bars become
visible and only 1/32 in. (0.8 mm) tread depth remains,
replace tire immediately. Using a worn tire can adversely
affect stability and handling, which could result in death
or serious injury. Use only Harley-Davidson approved
replacement tires. (00090b)

See 

Figure 1-40

. Arrows on tire sidewalls pinpoint location of

wear bar indicators.

Tread wear indicator bars will appear on tire tread surfaces
when 1/32 in. (0.8 mm) or less of tire tread remains. See

Figure 1-41

. Always replace tires before the tread wear indic-

ator bars appear.

When To Replace Tires

New tires are needed if any of the following conditions exist:

1.

Tread wear indicator bars become visible on the tread
surfaces.

2.

Tire cords or fabric become visible through cracked side-
walls, snags or deep cuts.

3.

A bump, bulge or split in the tire.

4.

Puncture, cut or other damage to the tire that cannot be
repaired.

om00846

Figure 1-40. Tire Sidewall Wear Bar Locator

om00845

Figure 1-41. Wear Bar Appearance (Typical)

WHEEL BEARINGS

1.

Replace when bearings exceed end play service wear
limit of 0.002 in. (0.051 mm).

2.

Inspect any time the wheels are removed.

a.

Inspect the play of the wheel bearings by finger while
they are in the wheel.

b.

Rotate the inner bearing race and check for abnormal
noise.

c.

Make sure bearing rotates smoothly.

3.

Check wheel bearings and axle spacers for wear and
corrosion. Excessive play or roughness indicates worn
bearings. Replace bearings in sets only. See 

2.4 WHEELS,

Sealed Wheel Bearings

.

WHEEL SPOKES

Spokes that are too tight can draw nipples through the rim
or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)

If nipples require more than one full turn to tighten spoke,
remove tire to check that spoke protrusion has not dam-
aged tube. (00526b)

1.

Raise motorcycle wheel off the ground.

NOTE

Perform the entire procedure for each spoke, one at a time.

HOME

2009 Sportster Service: Maintenance  1-37

2.

Mark one of the spokes with a reference mark to the rim.

3.

Loosen spoke 1/4 turn.

NOTES

•

Use a spoke torque wrench to tighten spokes.

•

Do not tighten spoke more than 1/4 turn past reference
mark. If more tension is needed, label spoke and check
after completing rest of wheel.

4.

Tighten spoke to reference mark. If torque is less then the
value listed in 

Table 1-10

, continue to tighten spoke until

it reaches the listed torque.

5.

Once the entire wheel has been checked, repeat pro-
cedure for each labeled spoke.

6.

If more than a few spokes were loose, true the entire wheel
following procedure under 

2.8 TRUING LACED WHEELS

.

Table 1-10. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

55 in-lbs (6.2 Nm)

All

HOME

1-38  2009 Sportster Service: Maintenance

1.12

PRIMARY CHAIN

INSPECTION

See 

Figure 1-42

. Check the primary chain for correct tension

by measuring its vertical free play through the primary chain
inspection cover (1) opening located near the top of the primary
cover (2).

NOTES

•

See 

Figure 1-43

. Refer to 

Table 1-11

. A properly adjusted

primary chain should have the specified vertical free play
in its upper strand. Be sure the measurement is taken
midway between engine and clutch sprockets with
sprockets rotated to the tightest chain position.

•

Always measure the vertical free play with the sprockets
rotated to several different positions. The tightest meas-
urement observed must be within specifications shown in

Table 1-11

.

•

The initial primary chain vertical free play specification
used at the Harley-Davidson assembly plant is 1/4-3/8 in.
(6.35-9.53 mm) with a cold engine. The 1/4 in. (6.35 mm)
minimum is only allowed at the absolute tightest point in
the drive, as measured with precision factory equipment.
If a chain has less than 1/4 in. (6.35 mm) vertical free play
(with a cold engine), adjust free play to the "field" specific-
ation of 3/8-1/2 in. (9.53-12.70 mm). The looser specifica-
tion will avoid overtightening, which might otherwise occur
during adjustment using "non-factory" equipment and
methods.

•

An opening between the primary drive and transmission
compartments allows the same lubricant supply to lubricate
moving parts in both compartments. For complete lubrica-
tion service on the primary chain, see 

1.14 TRANSMIS-

SION LUBRICANT

.

•

Since the primary chain runs in lubricant, little service will
be required other than checking lubricant level and chain
tension. If, through hard usage, the primary chain does
become worn, it must be replaced. Remove and install
the chain following the procedure under 

5.5 PRIMARY

DRIVE AND CLUTCH: XL MODELS

.

2

3

4

5

6

1

sm03278

1.

Primary chain inspection cover

2.

Primary cover

3.

Clutch inspection cover

4.

Drain plug

5.

Primary chain adjuster screw

6.

Lock nut

Figure 1-42. Primary Cover: All Models (XL Model Shown)

2

1

om00206

1.

Measurement point between sprockets

2.

Free play measurement

Figure 1-43. Primary Chain Vertical Free Play: Sportster

Models

Table 1-11. Primary Chain Adjustment: Sportster Models

MILLIMETERS

INCHES

FREE PLAY

9.5-12.7

3/8-1/2

COLD engine

6.3-9.5

1/4-3/8

HOT engine

ADJUSTMENT

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

HOME

2009 Sportster Service: Maintenance  1-39

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

2.32 HANDLEBARS, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screw

2.32 HANDLEBARS, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screw

6.40 RIGHT HANDLEBAR SWITCHES, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screws

6.41 LEFT HANDLEBAR SWITCHES, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screws

2.32 HANDLEBARS, Installation

16.3-24.4 Nm

12-18 ft-lbs

Handlebar upper clamp/speedometer
housing screw (XL 883C/XL 1200C)

2.32 HANDLEBARS, Installation

16.3-24.4 Nm

12-18 ft-lbs

Handlebar upper clamp/speedometer
housing screw (XL 883C/XL 1200C)

6.22 INDICATOR LAMP MODULE, Replacement:
All Other Models/all except XL 883C/XL 1200C/XL
1200L/XL 1200N 

16.3-24.4 Nm

12-18 in-lbs

Handlebar upper clamp screw

1.31 HEADLAMP ALIGNMENT, Headlamp
Adjustment: Sportster Models

40.7-47.5 Nm

30-35 ft-lbs

Headlamp Allen head capscrew

1.31 HEADLAMP ALIGNMENT, Headlamp
Adjustment: Sportster Models

14-27 Nm

120-240 in-lbs

Headlamp clamp nut

3.24 OIL PUMP: XL MODELS, Installation

6.8-10.2 Nm

60-90 in-lbs

High pressure feed hose fitting (to
crankcase)

3.24 OIL PUMP: XL MODELS, Installation

9.6-11.8 Nm

85-105 in-lbs

High pressure feed hose fitting nut

6.37 HORN, Replacement: Models with Front
Mounted Horn

8.1-12.2 Nm

72-108 in-lbs

Horn, front mounted, mounting screw

6.37 HORN, Replacement: Models with Side
Mounted Horn

6.8-20.4 Nm

60-180 in-lbs

Horn, side mounted, acorn nut

6.37 HORN, Replacement: Models with Side
Mounted Horn

9.0-11.3 Nm

80-100 in-lbs

Horn, side mounted, stud nut

2.4 WHEELS, Front Wheel/Cast front wheel 

21.7-32.6 Nm

16-24 ft-lbs

Hub plate mounting screw

4.10 INDUCTION MODULE: XL
MODELS, Assembly

6.8 Nm

60 in-lbs

IAC mounting screw

4.11 INDUCTION MODULE: XR
MODELS, Assembly

6.8 Nm

60 in-lbs

IAC mounting screw

4.12 IDLE AIR CONTROL (IAC), Installation: XL
Models

6.8 Nm

60 in-lbs

IAC mounting screw

4.12 IDLE AIR CONTROL (IAC), Installation: XR
Models

6.8 Nm

60 in-lbs

IAC mounting screw (XR models)

5.7 DRIVE BELT, Idler Pulley: XR Models Only

45-47 Nm

33-35 ft-lbs

Idler pulley bracket flanged nut: XR
models

5.7 DRIVE BELT, Idler Pulley: XR Models Only

95-109 Nm

70-80 ft-lbs

Idler pulley fastener: XR models

6.16 IGNITION AND LIGHT SWITCH, Installation

4.0-5.1 Nm

35-45 in-lbs

Ignition/light switch mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

4.0-5.1 Nm

34-45 in-lbs

Ignition switch mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

4.0-5.1 Nm

34-45 in-lbs

Ignition switch mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

27.1-32.5 Nm

20-24 ft-lbs

Induction module cover-to-cylinder head
fastener

4.11 INDUCTION MODULE: XR
MODELS, Installation

27.1-32.5 Nm

20-24 ft-lbs

Induction module cover-to-cylinder head
fastener

4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models

27.1-32.5 Nm

20-24 ft-lbs

Induction module cover-to-cylinder head
fastener

XVIII TORQUE VALUES