Harley Davidson Sportster Models 2009. Service Repair Manual - page 15

1.19

STEERING HEAD BEARINGS

ADJUSTMENT

Place suitable blocking under frame to raise front wheel
several inches off floor.

Remove all items that could interfere with front end swing
momentum. If clutch control cable inhibits front end swing,
disconnect it.

Place a strip of masking tape over tip of front fender.

Install a pointer mounted to a floor stand. The pointer is
positioned at the center of the fender with the front wheel
pointed straight ahead.

Repeatedly nudge the fender a short distance on one side
until the front end begins to "fall-away" (i.e., pivot about
its steering head center) by itself. Mark the point on the
tape where the front end begins to "fall-away." Repeat this
procedure in the opposite direction.

Measure the distance between the two "fall-away" marks.
The distance must be 1.0-2.0 in. (25-50 mm) for XL models
and 2.0-4.0 in. (50-100 mm) for XR models for proper
bearing adjustment.

See

Figure 1-73

. If the distance is not correct, perform the

following procedure:

Loosen the two lower bracket pinch screws (6) and
the fork stem pinch screw (4).

Remove fork stem bolt cap (1) (XL 1200R and
XL1200L models).

Loosen or tighten the fork stem bolt (2) until the "fall-
away" distance is 1.0-2.0 in. (25-50 mm) for XL
models or 2.0-4.0 in. (50-100 mm) for XR models.

NOTE

Loosen fork stem bolt if "fall-away" point is more than 2.0
in. (50 mm) for XL models or more than 4.0 in. (100 mm)
for XR models. If "fall-away" point is less than 1.0 in. (25
mm) for XL models or less than 2.0 in. (50 mm) for XR
models, tighten fork stem bolt.

Tighten fork stem pinch screw to 30-35 ft-lbs (40.7-
47.5 Nm).

Tighten lower bracket pinch screws to 30-35 ft-lbs
(40.7-47.5 Nm).

Install fork stem bolt cap (XL 1200R and XL1200L
models).

Recheck "fall-away."

LUBRICATION

See

Figure 1-73

. Disassemble the steering head assembly

and lubricate the tapered roller bearings (8) with HARLEY-
DAVIDSON SPECIAL PURPOSE GREASE. See

2.23 FORK

STEM AND BRACKET ASSEMBLY

for disassembly and

reassembly procedures.

HOME

1-60 2009 Sportster Service: Maintenance

sm01631

Screw (2)

Fork stem bolt cap (XL 1200R and XL1200L
models)

Tapered roller bearing (2)

Bolt

Bearing cup (2)

10.

Lower bracket

Washer

11.

Screw

Retaining ring

Upper bracket

Screw (4)

Figure 1-73. Steering Head Assembly (typical; XL model shown)

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2009 Sportster Service: Maintenance 1-61

1.20

SHOCK ABSORBER ADJUSTMENT

SHOCK ABSORBER PRELOAD
ADJUSTMENT: SPORTSTER MODELS

TOOL NAME

PART NUMBER

SPANNER WRENCH

HD-48645

SPANNER WRENCH

HD-94820-75A

See

Figure 1-74

. The rear shock absorber spring preload can

be adjusted for the weight the motorcycle is to carry. Increase
preload to accommodate additional weight of rider, passenger
and/or luggage. Reduce preload if carrying less weight.

NOTE

See

Figure 1-77

. The shock absorber has multiple preload

positions, depending on the motorcycle model.

Be sure both shock absorbers are adjusted to same pre-
load position. Improper adjustment can adversely affect
stability and handling, which could result in death or ser-
ious injury. (00036a)

See

Figure 1-75

. To adjust the rear shock spring preload, turn

spring adjusting cam to the desired position with a SPANNER
WRENCH (Part No. HD-94820-75A). When reducing preload,
cam should be rotated in opposite direction.

See

Figure 1-76

. On the XR 1200 model, use SPANNER

WRENCH (Part No. HD-48645) with a 3/8-inch ratchet and
extension to adjust the preload on the right side of the motor-
cycle.

The 883 Low and 1200N are designed for solo operation.
If you choose to add an adult passenger and/or cargo to
the vehicle, the ride quality will be compromised. See a
Harley-Davidson dealer for high capacity rear suspension
options. (00487e)

om00396

Rear shock absorber

Adjusting cam preload

Figure 1-74. Rear Shock Absorber Adjustment: Sportster

Models

om00844

Figure 1-75. Spanner Wrench (HD-94820-75A)

HOME

1-62 2009 Sportster Service: Maintenance

om01273

Spanner wrench

3/8-in. extension

Figure 1-76. Right Side Preload Adjustment: XR 1200 Model

om00196

Minimum preload adjustment

Maximum preload adjustment

Figure 1-77. Preload Adjustment

HOME

2009 Sportster Service: Maintenance 1-63

Horn Switch

Left Hand
Controls

TSM/TSSM/HFSM

Serial Data

Neutral Switch

Ground

Serial Data

Ground

Speedometer

Tachometer

Configuration For XR

Trip Reset

Switch

To Main
Harness

6
7
8
9

ACCY

15A

Ignition

Switch

[33]

30 Amp

MAXIFUSE

GND1

Powertrain

Ground

Point

IGN − I

BATT – B

ACC – A

ECM

[61B]

Fuseblocks

Top View

[119]

Accessories

Lights

Ignition

Fuel Pump

Start Relay System Relay

ECM

Battery

Spare

P&A IGN

Instruments

Spare

Engine Control

Open

To Instruments And

Indicator Lamps

[61]

[20B]

INSTR 15A

Battery

Oil

Pressure

Sending

Unit

Neutral
Switch

Ignition

Serial Data

Accessory

Ground

Trip Odometer Reset Switch

RPM x 100

Serial Data

Accessory

Ground

1
2

6
7
8

1
2

6
7
8

A
D

1
2
3
4

Receive Antenna

XMIT Antenna A
XMIT Antenna B

1
2
3
4

3
4

HFSM Only

Socket Connector

Pin Connector

(A Side)

(B Side)

15A

SWITCH
POSITION

RED/BLACK

RED

RED/GRAY

OFF
ACC.
IGNITION

Ignition Switch Legend

Dot indicates continuity with red
wire in switch position indicated

Horn

[20B]

[20A]

[5]

[163]

O/W

LGN/V

O/W

LGN/V

Y/BK

O/W

R/BK

R/GY

GN/Y

O/W

LGN/V

GN/Y

O/W

LGN/V

GN/Y

R/GY

R/BK

Engine Case

Ground Point

[122B]

[122A]

[120B]

[120A]

[136B]

[136A]

[24B]

[24A]

[78B]

[78A]

[208B]

[208A]

[30B]

[30A]

[108B]

[108A]

[20A]

[39B]

[39A]

et00124

Figure B-18. Horn and Instruments (XR): 2009 Sportster DOM. and INT. Models

Figure B-18.

Horn and Instruments (XR): 2009 Sportster DOM. and INT.

Models

Horn and Instruments (XR): 2009 Sportster DOM. and INT.

Models

1.21

REAR FORK BEARINGS

LUBRICATION

The rear fork bearings are sealed units and need no lubrication.

REPLACEMENT

See

2.25 REAR FORK

for rear fork bearing replacement pro-

cedure.

HOME

1-64 2009 Sportster Service: Maintenance

1.22

FRONT FORK OIL

CHANGING FORK OIL: XL MODELS

TOOL NAME

PART NUMBER

HARLEY-DAVIDSON PRO-LEVEL OIL
GAUGE

HD-59000-B

Draining Fork Oil

Have an assistant hold vehicle upright (not resting on jiffy
stand), with front fork pointed straight ahead.

Place a drain pan under bottom of right fork slider. See

Figure 1-78

. Remove drain screw and washer (5) from

bottom of one slider (4).

Drain fork oil by repeatedly compressing front suspension
slowly.

NOTE

If fork oil is emulsified, aerated or light brown in color, it has
been contaminated by water. Replace fork oil seals. See

2.21 FRONT FORK: XL MODELS

Replace drain screw and washer. Tighten to 13-17 in-lbs
(1.5-2.0 Nm).

Repeat previous steps for left side fork.

NOTE

Refer to

Table 1-18

. Fork oil amounts can be measured two

ways.

•

Use oz/ml measurement if fork is left in frame.

•

Use in/mm measurement if fork has been disassembled.

Table 1-18. Type E Fork Oil Amounts

MODEL

3.11

401

13.6

XL 883L/XL 1200N

122

4.80

364

12.3

XL 1200L

146

5.75

343

11.6

All other XL models

sm016337

Fork slider tube cap

O-ring

Slider tube

Fork slider

Fork oil drain screw with washer

Figure 1-78. Draining Front Fork Oil

Filling Fork Oil: Forks Assembled, in Frame

Block motorcycle under frame so that the front wheel is
raised off the ground slightly; this enables front fork to
extend fully and allows most of spring preload (compres-
sion force) to be relieved.

Incorrect amount of fork oil can adversely affect handling
and lead to loss of vehicle control, which could result in
death or serious injury. (00298a)

See

Figure 1-78

. Remove fork slider tube cap (1) with o-

ring (2) from each slider tube (3). Replace the o-ring if
damaged or worn.

Fill each slider tube/slider assembly with the amount of
TYPE "E" HYDRAULIC FORK OIL specified in

Table 1-18

HOME

2009 Sportster Service: Maintenance 1-65

Install each slider tube cap with o-ring. Tighten to 22-58
ft-lbs (29.9-78.7 Nm).

Lower motorcycle to the ground.

Filling Fork Oil: Forks Disassembled, out of
Frame

Position fork tube assembly upright. Remove spring and
compress assembly fully.

See

Table 1-18

. Pour approximately 14 fl oz. (414 ml)

TYPE "E" HYDRAULIC FORK OIL into fork.

See

Figure 1-79

. Using HARLEY-DAVIDSON PRO-LEVEL

OIL GAUGE (Part No. HD-59000-B), adjust oil level:

3.11 in. (79 mm) for XL883L/XL1200N.

4.80 in. (122 mm) for XL 1200L.

5.75 in. (146 mm) for all other XL models.

Install spring and slider tube cap with o-ring. Tighten to
22-58 ft-lbs (29.9-78.7 Nm).

Assemble fork and install in frame.

Repeat this procedure for other fork tube assembly.

sm01639

Fork slider tube

Pro Level Oil Gauge

Fork oil

Fork oil level

Figure 1-79. Refilling Front Fork Oil

CHANGING FORK OIL: XR MODELS

TOOL NAME

PART NUMBER

FORK TUBE HOLDER

HD-41177

FRONT FORK COMPRESSOR

HD-45966

INNER FORK NUT
REMOVER/INSTALLER

HD-47852

OIL LEVEL GAUGE

HD-59000B

Support the motorcycle so the front end is off the floor and
the forks are fully extended.

Remove the forks and drain the fork oil. See

2.22 FRONT

FORK: XR MODELS

HOME

1-66 2009 Sportster Service: Maintenance

Left Fork

Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)

NOTES

•

When using FRONT FORK COMPRESSOR be sure not
to bind the outer fork tube on the tool.

•

FRONT FORK COMPRESSOR (Part No. HD-45966)
comes with a cup and screw that are for FLT models only
and not to be used with this fork assembly.

sm03135

Figure 1-80. Clamp Fork and Remove Fork Cap

See

Figure 1-80

. Using FORK TUBE HOLDER (Part

No. HD-41177), mount fork assembly in vise.

Remove fork cap.