Harley Davidson Sportster Models 2009. Service Repair Manual - page 11

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Return Oil Manifold

9.5-12.2 Nm

84-108 in-lbs

Return oil manifold screw

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

61-68 Nm

45-50 ft-lbs

Rider footrest bracket mounting screw

1.13 CLUTCH, Adjustment

61-68 Nm

45-50 ft-lbs

Rider footrest support bracket mounting
screw

1.14 TRANSMISSION LUBRICANT, Transmission
Lubrication: Sportster Models

61-68 Nm

45-50 ft-lbs

Rider footrest support bracket mounting
screw

2.40 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS, Right
Footrest and Rear Brake Pedal Assembly

61-68 Nm

45-50 ft-lbs

Rider footrest support bracket mounting
screw

2.40 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS, Left
Footrest and Shift Lever Assembly

61-68 Nm

45-50 ft-lbs

Rider footrest support bracket mounting
screw

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS, Right
Footrest and Rear Brake Pedal Assembly

61-68 Nm

45-50 ft-lbs

Rider footrest support bracket mounting
screw

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS, Left
Footrest and Shift Lever Assembly

61-68 Nm

45-50 ft-lbs

Rider footrest support bracket mounting
screw

5.4 CLUTCH RELEASE MECHANISM, Assembly
and Installation

61-68 Nm

45-50 ft-lbs

Rider footrest support bracket mounting
screw

5.16 TRANSMISSION SPROCKET, Installation

61-68 Nm

45-50 ft-lbs

Rider footrest support mounting bracket

6.8 SPEEDOMETER: XL 883C/XL 1200C, Install-
ation/XL 883C/XL 1200C only 

0.9-1.4 Nm

8-12 in-lbs

Riser cover screw

6.24 TURN SIGNALS, Front Housing Replacement

0.9-1.4 Nm

8-12 in-lbs

Riser cover screw

6.39 HANDLEBAR SWITCH ASSEMBLIES, Con-
nectors/XL 883C/XL 1200C only 

0.9-1.4 Nm

8-12 in-lbs

Riser cover screw

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

10.9-17.6 Nm

96-156 in-lbs

Seat post mounting screw

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

10.9-17.6 Nm

96-156 in-lbs

Seat post screw

5.7 DRIVE BELT, Installation

4.1-6.8 Nm

36-60 in-lbs

Secondary drive belt deflector screws

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

10.9-16.3 Nm

96-144 in-lbs

Shifter peg: XR models

2.40 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS, Left
Footrest and Shift Lever Assembly

10.9-16.3 Nm

96-144 in-lbs

Shifter peg screw

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS, Left
Footrest and Shift Lever Assembly

10.9-16.3 Nm

96-144 in-lbs

Shifter peg screw

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS, Left
Footrest and Shift Lever Assembly

13.6-20.4 Nm

120-180 in-lbs

Shifter rod-to-shift lever screw

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS, Left
Footrest and Shift Lever Assembly

13.6-20.4 Nm

120-180 in-lbs

Shifter rod-to-shift lever screw

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CON-
TROLS, Adjusting Shift Pedal

13.6-20.4 Nm

120-180 in-lbs

Shifter rod-to-shift lever screw

TORQUE VALUES  XXIII

1

5

4

3

2

om00397

1.

Clutch diaphragm spring

2.

Clutch adjusting screw

3.

Quad-ring

4.

Primary cover

5.

Chaincase lubricant level

Figure 1-49. Chaincase Lubricant Level: Sportster Models

Changing Lubricant

1.

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

2.

When the engine reaches normal operating temperature,
turn the engine off and position motorcycle on jiffy stand.
This will allow the chaincase lubricant to drain out of
transmission.

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

3.

Remove main fuse. See 

6.38 MAIN FUSE, Removal

.

4.

See 

Figure 1-48

. Position a suitable container under

transmission drain plug (2).

5.

The drain plug is located under the clutch, on the under-
side of the chaincase. Remove drain plug and drain lub-
ricant.

6.

Position the motorcycle STRAIGHT UP and LEVEL. This
allows additional fluid to be drained from clutch compart-
ment.

NOTE

Dispose of lubricant in accordance with local regulations.

Do not over-tighten filler or drain plug. Doing so could
result in a lubricant leak. (00200b)

7.

Remove foreign material from magnetic drain plug.
Replace O-ring if torn or damaged. Apply LOCTITE 565
(white) to drain plug and tighten to 14-30 ft-lbs (19.0-40.7
Nm).

8.

Remove inspection cover from primary cover. See

1.14 TRANSMISSION LUBRICANT, Transmission Lubric-
ation: Sportster Models

.

NOTE

The filler access is the clutch inspection cover.

9.

Add 32 fluid ounces (946 milliliters) of GENUINE Harley-
Davidson FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT (Part No. 98851-05 quart)
through clutch inspection cover opening.

10. Install clutch inspection cover on primary cover. See

1.14 TRANSMISSION LUBRICANT, Transmission Lubric-
ation: Sportster Models

.

11. Install main fuse.

12. Start engine. Check for any lubricant leaks.

13. Turn engine off.

HOME

1-44  2009 Sportster Service: Maintenance

1.15

REAR BELT AND SPROCKETS

GENERAL

When a drive belt is replaced for any reason other than stone
damage, it is recommended that the transmission and rear
sprockets also be replaced to increase the longevity of the new
drive belt. In the case of stone damage, inspect sprockets for
damage and replace as required.

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
serious injury. (00339a)

CLEANING

Keep dirt, grease, oil, and debris off the belt and sprockets.
Clean the belt with a rag slightly dampened with a light cleaning
agent.

INSPECTION

Sprockets

NOTE

If chrome chips or gouges to rear sprocket are large enough
to be harmful, they will leave a pattern on the belt face.

1.

See 

Figure 1-50

. Inspect each tooth (1) of rear sprocket

for:

a.

Major tooth damage.

b.

Large chrome chips with sharp edges.

c.

Gouges caused by hard objects.

d.

Excessive loss of chrome plating (see next step).

2.

To check if chrome plating has worn off, drag a scribe or
sharp knife point across the bottom of a groove (2)
(between two teeth) with medium pressure.

a.

If scribe or knife point slides across groove without
digging in or leaving a visible mark, chrome plating
is still good.

b.

If scribe or knife points digs in and leaves a visible
mark, it is cutting the bare aluminum. A knife point
will not penetrate the chrome plating.

3.

Replace rear sprocket if major tooth damage or loss of
chrome exists.

1

2

sm03283

1.

Tooth

2.

Groove

Figure 1-50. Rear Sprocket

Idler Pulley: XR Models

See 

Figure 1-51

. Inspect idler pulley for signs of uneven wear.

Excessive lateral side play of 0.035 in. (0.9 mm) or roughness
indicates worn bearings. Replace idler pulley as an assembly.
See 

5.7 DRIVE BELT

.

sm00093

Figure 1-51. Measuring Lateral Side Play on Idler Pulley

Rear Belt

See 

Figure 1-52

. Inspect drive belt for:

•

Cuts or unusual wear patterns.

•

Outside edge bevelling (8). Some bevelling is common,
but it indicates that sprockets are misaligned.

•

Outside ribbed surface for signs of stone puncture (7). If
cracks/damage exists near edge of belt, replace belt
immediately. Damage to center of belt will require belt
replacement eventually, but when cracks extend to edge
of belt, belt failure is imminent.

•

Inside (toothed portion) of belt for exposed tensile cords
(normally covered by nylon layer and polyethylene layer).
This condition will result in belt failure and indicates worn

HOME

2009 Sportster Service: Maintenance  1-45

transmission sprocket teeth. Replace belt and transmission
sprocket.

•

Signs of puncture or cracking at the base of the belt teeth.
Replace belt if either condition exists.

•

Replace belt if conditions 2, 3, 6 or 7 (on edge of belt)
exist.

NOTE

Condition 1 may develop into 2 or 3 over time. Condition 1 is
not grounds for replacing the belt, but it should be watched
closely before condition 2 develops which will require belt
replacement.

1

3

5

7

2

4

6

8

Stone

Belt cross-section

Sprocket side
of belt

sm01390

Figure 1-52. Drive Belt Wear Patterns

Table 1-12. Drive Belt Wear Analysis

REQUIRED ACTION

CONDITION

PATTERN

OK to run, but monitor condition.

Internal tooth cracks (hairline)

1

Replace belt.

External tooth cracks

2

Replace belt.

Missing teeth

3

OK to run, but monitor condition.

Chipping (not serious)

4

OK to run, but monitor condition.

Fuzzy edge cord

5

Replace belt and sprocket.

Hook wear

6

Replace belt if damage is on the edge.

Stone damage

7

OK to run, but monitor condition.

Bevel wear (outboard edge only)

8

Check idler bearings and bracket attachment.

Excess edge wear

XR only

HOME

1-46  2009 Sportster Service: Maintenance

1.16

REAR BELT DEFLECTION

REAR DRIVE BELT: SPORTSTER MODELS

TOOL NAME

PART NUMBER

BELT TENSION GAUGE

HD-35381A

General

The inner tooth surface of the secondary belt has a thin coating
of polyethylene lubricant. During initial operation, this coating
will wear off as it is burnished into the belt fabric. This is a
normal condition and not an indication of belt wear.

Belt tension is set at the factory and should be checked after
the first 1000 miles (1600 kilometers), at scheduled mainten-
ance intervals, and after a hard ride.

Gauging Deflection

Check belt deflection at the loosest spot in the belt with the
transmission in neutral and the motorcycle at ambient temper-
ature.

1.

With the motorcycle unladen and resting on its jiffy stand,
fit the BELT TENSION GAUGE (Part No. HD-35381A) on
the belt.

a.

See 

Figure 1-56

. On XR 1200 model, fit BELT TEN-

SION GAUGE half-way between the idler wheel and
rear sprocket.

b.

See 

Figure 1-55

. On all other models, position the

gauge half-way between the transmission and rear
wheel sprockets.

2.

With the BELT TENSION GAUGE set to 0 lbs. (0 kg), note
the current belt position.

a.

See 

Figure 1-54

. On XR 1200 model, note the belt

position according to the graduations on the front of
the debris deflector.

b.

See 

Figure 1-53

. On all other models, note the belt

position according to the graduations on the belt
deflection window located on the rear drive belt guard.

3.

Using the BELT TENSION GAUGE, apply 10 lbs. (4.5 kg)
of force to the bottom belt. Count the number of gradu-
ations between the original belt position and after applying
the force. Multiply this number by 1/8 in. (3.2 mm) to
determine the deflection.

4.

Refer to 

Table 1-13

 for the recommended deflection. If

belt tension adjustment is necessary, see a Harley-Dav-
idson dealer or follow the belt deflection adjustment pro-
cedure in the Service Manual.

Be sure wheel and brake caliper are aligned. Riding with
a misaligned wheel or brake caliper can cause the brake
disc to bind and lead to loss of control, which could result
in death or serious injury. (00050a)

NOTE

When gauging deflection, check the rear brake caliper position
on rear brake disc. Disc should run true within brake caliper.

Table 1-13. Belt Deflection: Sportster Models

MILLIMETERS

INCHES

MODELS

6.4-7.9

1/4-5/16

XL 883C, XL 883L, XL
1200C, XL 1200L, XL
1200N

14.3-15.9

9/16-5/8

XL 883, XL 883R, XL
1200R

6.4-9.5

1/4-3/8

XR 1200

2

1

om00851

1.

Rear drive belt

2.

Deflection graduations 1/8 in. (3.2 mm) apart

Figure 1-53. Belt Deflection Window (typical)

HOME

2009 Sportster Service: Maintenance  1-47

4.3

EFI DIAGNOSTIC INTRODUCTION

SYSTEM PROBLEMS

All system problems fall into at least one of three general cat-
egories.

No Start

The engine cranks over freely, but will not start. This does not
include situations where the engine will not crank, such as a
security disabled starter, dead battery, etc. This condition
assumes that all obvious checks (fuel in tank, etc.) have been
made.

Poor Performance

The engine starts but there are performance problems. These
problems may include poor fuel economy, rough idle, engine
misfire, engine hesitation, severe spark knock, etc.

Check Engine Lamp

See 

Figure 4-3

. The check engine lamp indicates the Electronic

Control Module (ECM) has determined a fault condition exists.
There may also be starting or performance problems.

ed02839

Figure 4-3. Check Engine Lamp (Typical)

RESOLVING PROBLEMS

To resolve system problems, five basic steps are involved. In
order of occurrence, they are:

1.

Check for DTCs by using odometer self-diagnostics. See

4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES:
EFI

.

2.

Retrieve DTCs by using odometer self-diagnostics. See

4.6 ODOMETER SELF-DIAGNOSTICS

.

3.

Diagnose system problems. This involves using special
tools and the diagnostic flowcharts in this section.

4.

Correct problems through the replacement and/or repair
of the affected components.

5.

After repairs are performed, the work must be validated.
This involves clearing the DTCs and confirming proper
vehicle operation as indicated by the lack of DTCs.

HOME

2009 Sportster Diagnostics:  Engine Management  4-5

4.4

CHECKING FOR DIAGNOSTIC TROUBLE
CODES: EFI

CHECK ENGINE LAMP

To diagnose system problems, start by observing the behavior
of the check engine lamp.

NOTES

•

See 

Figure 4-4

. "Key ON" means that the Ignition Switch

is turned to IGNITION and the Engine Stop Switch is set
to RUN (although the engine is not running).

•

When the Ignition Switch is turned ON, the check engine
lamp will illuminate for approximately four seconds and
then turn off.

•

If the check engine lamp is not illuminated at Key ON or
if it fails to turn OFF after the initial four-second period,
then see 

4.6 ODOMETER SELF-DIAGNOSTICS

.

•

If the check engine lamp comes on late (after 20 seconds),
the problem is likely a serial data bus failure. Test for
Diagnostic Trouble Codes (DTCs) using odometer self
diagnostics. See 

4.6 ODOMETER SELF-DIAGNOSTICS

.

1.

See 

Figure 4-5

. After lamp turns off after being illuminated

for the first four-second period, one of three situations may
occur.

a.

The lamp remains off. This indicates there are no
current fault conditions or stored DTCs currently
detected by the Electronic Control Module (ECM).

b.

The lamp stays off for only four seconds and then
comes back on for an eight-second period. This
indicates a code is stored, but no current DTC exists.

c.

The lamp remains on beyond the eight-second period.
This indicates a current DTC exists.

2.

See 

4.4 CHECKING FOR DIAGNOSTIC TROUBLE

CODES: EFI, Code Types

 for a complete description of

DTC formats.

NOTE

Some DTCs can only be fully diagnosed during actuation. For
example, a problem with the ignition coil will be considered a
current fault even after the problem is corrected, since the ECM
will not know of its resolution until after the coil is exercised by
vehicle start sequence. In this manner, there may sometimes
be a false indication of the current trouble code.

OFF

ACC.

IGNITION

3

1

2

ed02814

1.

Ignition OFF

2.

Accessory (ACC) ON

3.

Ignition ON

Figure 4-4. Ignition Switch

HOME

4-6  2009 Sportster Diagnostics:  Engine Management