Content .. 8 9 10 11 ..

Harley Davidson Sportster Models 2009. Service Repair Manual - page 10

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

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

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-induction
module fastener

4.11 INDUCTION MODULE: XR
MODELS, Installation

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-induction
module fastener

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

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-induction
module fastener

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

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-wire form
fastener

4.11 INDUCTION MODULE: XR
MODELS, Installation

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-wire form
fastener

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

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-wire form
fastener

4.10 INDUCTION MODULE: XL MODELS, Install-
ation

9.5-12.2 Nm

84-108 in-lbs

Induction module mounting bracket
screw

4.10 INDUCTION MODULE: XL
MODELS, Assembly

4.0 Nm

35 in-lbs

Induction module-to-intake manifold
screw

4.10 INDUCTION MODULE: XL
MODELS, Assembly

6.8 Nm

60 in-lbs

Induction module-to-intake manifold
screw

2.36 REAR FENDER: XR MODELS, Installation

8.1-13.6 Nm

72-120 in-lbs

Inner fender screw: XR models

1.22 FRONT FORK OIL, Changing Fork Oil: XR
Models/Hand tighten. Then tighten to torque.

93-113 Nm

69-83 ft-lbs

Inner fork nut, right: XR models

2.22 FRONT FORK: XR MODELS, Assembly/Hand
tighten. Then tighten to torque.

93-113 Nm

69-83 ft-lbs

Inner fork nut, right: XR models

3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers

24.4-29.8 Nm

18-22 ft-lbs

Inner rocker cover bolt, large

3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers

15.3-17.5 Nm

135-155 in-lbs

Inner rocker cover bolt, small

3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers

15.3-17.5 Nm

135-155 in-lbs

Inner rocker cover screw

4.10 INDUCTION MODULE: XL MODELS, Install-
ation

10.9-13.6 Nm

96-120 in-lbs

Intake manifold mounting screw

4.11 INDUCTION MODULE: XR
MODELS, Installation

10.9-13.6 Nm

96-120 in-lbs

Intake manifold mounting screw

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

40.7-44.7 Nm

30-33 ft-lbs

Interconnect bracket-to-frame fastener

2.28 FRONT ENGINE MOUNT/ISOLATOR, Install-
ation

33.9-47.5 Nm

25-35 ft-lbs

Isolator (front) mounting bracket screw

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

33.9-47.5 Nm

25-35 ft-lbs

Isolator (front) mounting bracket screw

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

33.9-47.5 Nm

25-35 ft-lbs

Isolator mount screw, front

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

33.9-47.5 Nm

25-35 ft-lbs

Isolator mount screw, front

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

33.9-47.5 Nm

25-35 ft-lbs

Isolator mount screw, rear

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

33.9-47.5 Nm

25-35 ft-lbs

Isolator mount screw, rear

TORQUE VALUES XIX

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

6.34 JIFFY STAND SWITCH: INTERNATIONAL
MODELS, Installation

10.9-13.6 Nm

96-120 in-lbs

Jiffy stand switch screw

2.34 REAR FENDER: ALL XL MODELS EXCEPT
XL 1200N, Installation

2.3-2.8 Nm

20-25 in-lbs

License plate bracket mounting screw

6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)

1.2-1.3 Nm

14-16 in-lbs

License plate lamp housing screw

6.33 ELECTRICAL CADDIES, Wire Harness
Caddy: XL Models

4.0-5.1 Nm

35-45 in-lbs

Light switch bracket screw

6.33 ELECTRICAL CADDIES, Wire Harness
Caddy: XR Models

4.0-5.1 Nm

35-45 in-lbs

Light switch bracket screw

6.14 STARTER SOLENOID, Solenoid Contacts

7.3-9.0 Nm

65-80 in-lbs

Long post jam nut

2.23 FORK STEM AND BRACKET
ASSEMBLY, Assembly and Installation

40.7-47.5 Nm

30-35 ft-lbs

Lower fork bracket pinch screw

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

61.0-67.8 Nm

45-50 ft-lbs

Lower front retainer plate fastener

2.32 HANDLEBARS, Installation

40.7-54.3 Nm

30-40 ft-lbs

Lower handlebar clamp bolts

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

40.7-44.7 Nm

30-33 ft-lbs

Lower muffler mount nut

2.17 REAR BRAKE CALIPER: XR
MODELS, Installation

40.7-61.0 Nm

30-45 ft-lbs

Lower shock absorber fastener

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

40.7-61.0 Nm

30-45 ft-lb

Lower shock absorber fastener

5.7 DRIVE BELT, Installation

61-68 Nm

45-50 ft-lbs

Lower shock absorber screw

5.7 DRIVE BELT, Installation

61-68 Nm

45-50 ft-lbs

Lower shock absorber screw

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

10.9-16.3 Nm

96-144 in-lbs

Mirror stem lock nut

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

10.9-16.3 Nm

96-144 in-lbs

Mirror stem lock nut

2.43 PASSENGER FOOTRESTS, XR Models

20.4-25.8 Nm

15-19 ft-lbs

Muffler bracket-to-footrest bracket screw
(XR)

4.15 EXHAUST SYSTEM: XL MODELS, Installation

40.7-44.8 Nm

30-33 ft-lbs

Muffler interconnect bracket mounting
screw

5.16 TRANSMISSION SPROCKET, Installation

40.7-44.8 Nm

30-33 ft-lbs

Muffler interconnect bracket mounting
screw

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

16.9-20.3 Nm

120-180 in-lbs

Muffler-to-front muffler mount fastener

4.15 EXHAUST SYSTEM: XL MODELS, Installation

20.4-25.8 Nm

15-19 ft-lbs

Muffler-to-interconnect bracket screw

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

16.9-20.3 Nm

120-180 in-lbs

Muffler-to-muffler bolt

4.15 EXHAUST SYSTEM: XL MODELS, Installation

51.6-58.4 Nm

38-43 ft-lbs

Muffler torca clamp nut

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

16.9-20.3 Nm

120-180 in-lbs

Muffler-to-rear muffler mount fastener

5.15 TRANSMISSION INSTALLATION, Assembling
Crankcases

13.6-20.3 Nm

120-180 in-lbs

Neutral indicator switch

6.31 NEUTRAL INDICATOR SWITCH, Replace-
ment

13.6-20.3 Nm

120-180 in-lbs

Neutral indicator switch

4.15 EXHAUST SYSTEM: XL MODELS, Installation

39.3-59.7 Nm

29-44 ft-lbs

O2 sensor

XX TORQUE VALUES

See

Figure 1-42

. The primary chain can be adjusted without

removing the primary cover (2). Proceed as follows:

Unplug main fuse. See

6.38 MAIN FUSE

Remove two hex socket screws securing primary chain
inspection cover (1).

Rotate sprockets to find tightest point on primary chain.

Do not adjust the primary chain tighter than specified.
Running chain too tight will result in excessive wear.
(00202a)

Loosen lock nut (6). Using a 1/4-inch allen wrench, turn
chain adjuster screw (5) clockwise (inward) to reduce free

play or counterclockwise (outward) to increase free play.
Vertical free play must fall within the limits specified in

Table 1-11

NOTE

If vertical free play cannot be set within the limits specified in

Table 1-11

, then primary chain and/or chain adjuster are worn

beyond adjustment limits. Replace parts as necessary. See

5.3 PRIMARY CHAIN ADJUSTER

See

Figure 1-42

. When tension is set correctly, hold chain

adjusting screw with allen wrench and tighten lock nut (6)
to 20-25 ft-lbs (27.1-33.9 Nm).

Install primary chain inspection cover (1) and new gasket.
Tighten hex socket screws to 84-120 in-lbs (9.5-13.6 Nm).

Plug in main fuse. See

6.38 MAIN FUSE

HOME

1-40 2009 Sportster Service: Maintenance

1.13

CLUTCH

ADJUSTMENT

All models feature a primary cover and a quick-release clutch
cable to simplify both clutch service and adjustment. See

Figure 1-44

. Clutch cable adjuster is located in middle of cable,

adjacent to left frame downtube.

sm01436

Figure 1-44. Clutch Cable Adjuster Location (typical; XL

model shown)

See

Figure 1-45

. Slide rubber boot (1) off cable adjuster

(2).

Holding cable adjuster with 1/2 inch wrench, loosen jam
nut (3) using a 9/16 inch wrench. Back jam nut away from
cable adjuster. Screw adjuster toward jam nut to introduce
a large amount of free play at hand lever.

XL models equipped with mid-mount foot controls:
remove left side rider footrest and mounting bracket
assembly. See

2.40 RIDER FOOT CONTROLS: XL

MODELS EQUIPPED WITH MID-MOUNT CONTROLS

for removal.

XR models: remove left side rider footrest, mounting
bracket assembly, and shift linkage. See

2.42 RIDER

FOOT CONTROLS: XR MODELS

for removal.

See

Figure 1-46

. Remove six screws (1) and remove

clutch inspection cover (2). Remove and discard quad ring
(7).

Remove hex lockplate with attached spring (3) from flats
of adjusting screw assembly (8). Turn adjusting screw
counterclockwise until resistance is felt. Back off adjusting
screw 1/4 turn.

Slide hex lockplate with spring onto flats of adjusting
screw. If necessary, turn adjusting screw clockwise slightly

so that lockplate slides onto flats while also fitting within
recess of outer ramp.

sm01437

Rubber boot

Cable adjuster

Jam nut

Cable end

Figure 1-45. Clutch Cable Adjuster Mechanism

Install new quad ring. Verify that quad ring is fully seated
in groove of primary cover. Install clutch inspection cover
and secure with six screws. Tighten screws in a crosswise
pattern to 84-108 in-lbs (9.5-12.2 Nm).

See

Figure 1-45

. Turn cable adjuster (2) clockwise away

from jam nut (3) until slack is eliminated.

See

Figure 1-47

. Pull clutch cable ferrule away from clutch

lever bracket to check free play. Turn cable adjuster as
necessary to obtain 1/16-1/8 in. (1.6-3.2 mm) free play
between end of cable ferrule and clutch lever bracket.

10. See

Figure 1-45

. Hold adjuster (2) with 1/2 inch wrench.

Using 9/16 inch wrench, tighten jam nut (3) against cable
adjuster. Cover cable adjuster mechanism with rubber
boot (1).

11. Secure cable in cable retainers attached to down tube.

12. XL models equipped with mid-mount foot controls:

install left side rider footrest and mounting bracket
assembly. Tighten footrest bracket mounting screws to
45-50 ft-lbs (61-68 Nm). See

2.40 RIDER FOOT CON-

TROLS: XL MODELS EQUIPPED WITH MID-MOUNT
CONTROLS

for installation.

XR models: install left side rider footrest, shifter and
mounting bracket assembly, and shift linkage. Tighten
footrest bracket mounting screws to 45-50 ft-lb (61.0-67.8
Nm). Tighten linkage fastener to 10-15 ft-lbs (13.6-20.3
Nm). See

2.42 RIDER FOOT CONTROLS: XR MODELS

for installation.

HOME

2009 Sportster Service: Maintenance 1-41

sm03279

Screw (6)

Clutch inspection cover

Hex lockplate and spring

Nut

Ramp assembly

Coupling

Quad ring

Clutch adjusting screw assembly

Primary cover

10. Clutch cable

Figure 1-46. Clutch Release Mechanism

sm01439

Clutch cable

Cable ferrule

Clutch lever bracket

Adjustment range

Figure 1-47. Clutch Freeplay: Adjust for 1/16-1/8 in. (1.6-3.2

mm) Gap Between Ferrule and Bracket

HOME

1-42 2009 Sportster Service: Maintenance

1.14

TRANSMISSION LUBRICANT

TRANSMISSION LUBRICATION:
SPORTSTER MODELS

Refer to

Table 1-3

. The transmission should be drained and

refilled with fresh lubricant at proper intervals. For best results,
drain lubricant while hot.

NOTE

When checking the transmission lubricant level, motorcycle
should be standing STRAIGHT UP, not leaning on the jiffy
stand. Keep motorcycle upright for a short period of time to
equalize lubricant level in the transmission compartments.

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

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. (00047d)

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incom-
plete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)

Check Lubricant Level

Ride motorcycle until engine is warmed up to normal
operating temperature.

Position motorcycle straight up.

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

Remove main fuse. See

6.38 MAIN FUSE, Removal

XL models equipped with mid-mount foot controls:
remove left side rider footrest and mounting bracket
assembly. See

2.40 RIDER FOOT CONTROLS: XL

MODELS EQUIPPED WITH MID-MOUNT CONTROLS

for removal.

XR models: remove left side rider footrest, mounting
bracket assembly, and shift linkage. See

2.42 RIDER

FOOT CONTROLS: XR MODELS

for removal.

See

Figure 1-48

. Remove screws with washers from clutch

inspection cover (1). Remove clutch inspection cover from
primary cover.

NOTE

The filler access is the clutch inspection cover.

See

Figure 1-49

. Verify that lubricant level is even with

bottom of clutch diaphragm spring.

NOTE

Add only enough of GENUINE Harley-Davidson FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT
(Part No. 98851-05 quart) through clutch inspection cover
opening until the lubricant reaches the bottom of clutch dia-
phragm spring.

XL models equipped with mid-mount foot controls:
install left side rider footrest and mounting bracket
assembly. Tighten footrest bracket mounting screws to
45-50 ft-lbs (61-68 Nm). See

2.40 RIDER FOOT CON-

TROLS: XL MODELS EQUIPPED WITH MID-MOUNT
CONTROLS

for installation.

2.42 RIDER FOOT CONTROLS: XR MODELS

for installation.

Install main fuse.

10. Start engine. Check for any lubricant leaks.

11. Turn engine off.

om00908a

Clutch inspection cover

Drain plug

Primary chain inspection cover

Figure 1-48. Primary Cover: Sportster Models (XL Model

Shown)

HOME

2009 Sportster Service: Maintenance 1-43

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

1.4 MAINTENANCE SCHEDULE, General

19.0-40.7 Nm

14-30 ft-lbs

Primary chaincase drain plug

1.14 TRANSMISSION LUBRICANT, Transmission
Lubrication: Sportster Models/Apply LOCTITE
THREADLOCKER 565 (white).

19.0-40.7 Nm

14-30 ft-lbs

Primary chaincase drain plug

1.12 PRIMARY CHAIN, Adjustment

9.5-13.6 Nm

84-120 in-lbs

Primary chain inspection cover

1.4 MAINTENANCE SCHEDULE, General

9.5-13.6 Nm

84-120 in-lbs

Primary chain inspection cover screw

1.12 PRIMARY CHAIN, Adjustment

27.1-33.9 Nm

20-25 ft-lbs

Primary chain lock nut

5.3 PRIMARY CHAIN ADJUSTER, Installation

11.3-13.5 Nm

100-120 in-lbs

Primary cover screw

5.3 PRIMARY CHAIN ADJUSTER, Installation

19.0-40.7 Nm

14-30 ft-lbs

Primary drain plug

3.16 TOP END OVERHAUL: ASSEMBLY, Push
Rods, Covers, and Retainers

9.0-12.4 Nm

80-110 in-lbs

Push rod retainer screw

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Oil Pump Lines

12.2-17.6 Nm

108-156 in-lbs

Quick connect fitting

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

12.2-17.6 Nm

108-156 in-lbs

Quick connect fitting, cylinder head
return oil

2.17 REAR BRAKE CALIPER: XR
MODELS, Installation

19.6-24.5 Nm

14-18 ft-lbs

Rear caliper mounting bolt

2.17 REAR BRAKE CALIPER: XR
MODELS, Installation

19.6-24.5 Nm

14-18 ft-lbs

Rear caliper pin bolt

2.35 REAR FENDER AND LICENSE PLATE
BRACKET: XL 1200N, Assembly and Installation

2.3-2.8 Nm

20-25 in-lbs

Rear fender brace screw

6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)

2.3-2.8 Nm

20-25 in-lbs

Rear fender brace screw

2.35 REAR FENDER AND LICENSE PLATE
BRACKET: XL 1200N, Assembly and Installation

14.9-24.4 Nm

132-216 in-lbs

Rear fender support screw

2.25 REAR FORK, Installation

81.4-95.0 Nm

60-70 ft-lbs

Rear fork pivot/engine mount bolt

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

81.4-95.0 Nm

60-70 ft-lbs

Rear fork pivot/engine mount bolt

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

81.4-95.0 Nm

60-70 ft-lbs

Rear fork pivot/engine mount bolt

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

81.4-95.0 Nm

60-70 ft-lbs

Rear fork pivot/engine mount bolt

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

20.3-27.1 Nm

15-20 ft-lbs

Rear muffler mount-to-frame fastener

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

9.5-12.2 Nm

84-108 in-lbs

Rear rigid oil line retainer screw

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Oil Pump Lines

9.5-12.2 Nm

84-108 in-lbs

Rear rigid oil line retainer screw

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

40.7-44.7 Nm

30-33 ft-lbs

Rear sprocket cover screw: XR models

5.7 DRIVE BELT, Installation

40.7-44.7 Nm

30-33 ft-lbs

Rear sprocket cover screw: XR models

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

8.1-13.6 Nm

72-120 in-lbs

Rear stop light switch bracket screw

6.24 TURN SIGNALS, Rear Housing Replacement

3.4-4.5 Nm

30-40 in-lbs

Rear turn signal housing screws: XR
models

6.24 TURN SIGNALS, Rear Housing Replacement

10.9-17.6 Nm

96-156 in-lbs

Rear turn signal housing-to-stalk

2.35 REAR FENDER AND LICENSE PLATE
BRACKET: XL 1200N, Assembly and Installation

14.9-24.4 Nm

132-216 in-lbs

Rear turn signal stalk nut

XXII TORQUE VALUES

Content .. 8 9 10 11 ..