Harley Davidson Sportster Models 2009. Service Repair Manual

Tilt headlamp up or down to properly aim it in relation to
the horizontal line and, at the same time, turn it right or
left to direct light beam straight ahead.

Tighten headlamp clamp nut to 120-240 in-lbs (14-27 Nm)
after lamp is properly positioned. Install snap plug in
headlamp bracket.

om00210

Snap plug

Headlamp bracket

Figure 1-111. Headlamp Snap Plug: Sportster Models (XL

Model Shown)

om00211

Figure 1-112. Headlamp Clamp Nut: Sportster Models (XL

Model Shown)

HOME

1-84 2009 Sportster Service: Maintenance

1.32

FLUID AND LUBRICANT REQUIREMENTS

BRAKE FLUID

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)

Use only Harley-Davidson brand D.O.T. 4 BRAKE FLUID.

BRAKE COMPONENT GREASE

Use only CCI #20 BRAKE GREASE to lubricate master cylinder
bores, pistons, and primary and secondary cups. Use only
G40M BRAKE GREASE to lubricate all other brake system
components.

FRONT FORK OIL

Use only HARLEY-DAVIDSON TYPE "E" HYDRAULIC FORK
OIL.

PRIMARY DRIVE/TRANSMISSION
LUBRICANT

Use only GENUINE HARLEY-DAVIDSON FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT.

ENGINE OIL

Engine oil is a major factor in the performance and service life
of the engine. Refer to

Table 1-21

. Always use the proper grade

of oil for the lowest temperature expected before the next
scheduled oil change.

If it is necessary to add oil and Harley-Davidson oil is not
available, use an oil certified for diesel engines. Acceptable
diesel engine oil designations include CF, CF-4, CG-4 and CH-
4. The preferred viscosities for the diesel engine oils, in des-
cending order, are 20W-50, 15W-40 and 10W-40. At the first
opportunity, see a Harley-Davidson dealer to change back to
100 percent Harley-Davidson oil.

Table 1-21. Recommended Engine Oils

COLD WEATHER

STARTS BELOW 50° F

(10° C)

LOWEST AMBIENT

TEMPERATURE

H-D RATING

VISCOSITY

H-D TYPE

Excellent

Below 40° F (4° C)

HD 360

SAE 10W40

H-D Multi-grade

Good

Above 40° F (4° C)

HD 360

SAE 20W50

H-D Multi-grade

Poor

Above 60° F (16° C)

HD 360

SAE 50

H-D Regular Heavy

Poor

Above 80° F (27° C)

HD 360

SAE 60

H-D Extra Heavy

HOME

2009 Sportster Service: Maintenance 1-85

1.33

CRITICAL FASTENERS

INSPECTION

Inspect critical fasteners at the scheduled service intervals.

Replace any fasteners that are damaged or missing.

Checking Torques on Fasteners

Refer to

Table 1-22

. Attempt to turn the fastener using a torque

wrench set to the minimum torque specification for that
fastener. If the fastener does not rotate, the fastener torque

has been maintained. If the fastener rotates, remove it to
determine if it has a locking agent.

If it has a locking agent, clean all locking material from the
threaded hole. Replace the fastener with a new one or clean
the original fastener threads and apply the appropriate locking
agent (see appropriate procedure). Install and tighten the
fastener to specification.

If the fastener does not have a locking agent, install and tighten
to specification.

Table 1-22. Critical Fasteners

TORQUE

FASTENER

SYSTEM

4.0-5.1 Nm

35-45 in-lbs

Upper and lower switch housing screws

Hand controls

12.2-14.9 Nm

108-132 in-lbs

Clutch lever handlebar clamp screws

12.2-14.9 Nm

108-132 in-lbs

Master cylinder handlebar clamp screws

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screws

Engine

33.9-47.5 Nm

25-35 ft-lbs

Upper front stabilizer link frame bracket
mounting screws

74.6-88.2 Nm

55-65 ft-lbs

Upper front stabilizer link engine bracket
mounting screws

33.9-47.5 Nm

25-35 ft-lbs

Lower front stabilizer link frame bracket
mounting screws

81.4-95.0 Nm

60-70 ft-lbs

Front isolator mounting bolt

81.4-95.0 Nm

60-70 ft-lbs

Rear fork pivot/engine mount bolts

33.9-47.5 Nm

25-35 ft-lbs

Front isolator mounting bracket screws (left
side)

33.9-47.5 Nm

25-35 ft-lbs

Rear isolator mounting bracket screws (left
side)

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolts

Brakes

21.7-32.6 Nm

16-24 ft-lbs

Front brake disc mounting screws

40.7-61.1 Nm

30-45 ft-lbs

Rear brake disc mounting screws

1.0-2.0 Nm

9-17 in-lbs

Front master cylinder reservoir cover screws

23.1-29.9 Nm

17-22 ft-lbs

Rear master cylinder mounting screws: XL

8.1-10.9 Nm

72-96 in-lbs

Rear master cylinder mounting screws: XR

23.1-29.9 Nm

17-22 ft-lbs

Rear master cylinder bracket-to-frame
mounting screws: XL

61-67.8 Nm

45-50 ft-lbs

Rear master cylinder/footpeg bracket-to-
frame mounting screws: XR

38.0-51.6 Nm

28-38 ft-lbs

Front brake caliper mounting bolts

81-88 Nm

60-65 ft-lbs

Front

Axle nuts

129-142 Nm

95-105 ft-lbs

Rear

HOME

1-86 2009 Sportster Service: Maintenance

Table 1-22. Critical Fasteners

TORQUE

FASTENER

SYSTEM

40.7-47.5 Nm

30-35 ft-lbs

Lower bracket pinch screws

Front fork/handlebars

40.7-47.5 Nm

30-35 ft-lbs

Upper bracket pinch screws

31.2-36.6 Nm, loosen,

23-27 ft-lbs, loosen,

Fork stem bolt

8.1-10.9 Nm

72-96 in-lbs

40.7-47.5 Nm

30-35 ft-lbs

Fork stem pinch screw

28.5-36.6 Nm

21-27 ft-lbs

Front axle pinch screw: XL

55.6-65.1 Nm

41-48 ft-lbs

Front axle pinch screw: XR

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp mounting screw

40.7-54.3 Nm

30-40 ft-lbs

Riser mounting bolts

81.3 Nm, loosen 180°, 108

60 ft-lbs, loosen 180°, 80 ft-

lbs

Rear sprocket mounting screws

Final drive

HOME

2009 Sportster Service: Maintenance 1-87

1.34

STORAGE

GENERAL

If the motorcycle will not be operated for several months, such
as during the winter season, there are several things which
should be done to protect parts against corrosion, to preserve
the battery and to prevent the buildup of gum and varnish in
the fuel system.

This work should be performed following Service Manual pro-
cedures.

PLACING IN STORAGE

TOOL NAME

PART NUMBER

STORAGE COVER

98716-87A

Do not store motorcycle with gasoline in tank within the
home or garage where open flames, pilot lights, sparks or
electric motors are present. Gasoline is extremely flam-
mable and highly explosive, which could result in death
or serious injury. (00003a)

Run motorcycle until engine is at normal operating temper-
ature. Stop the engine then drain the oil tank, install a new
oil filter, and fill oil tank with the proper grade oil. Check
the transmission lubricant level.

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Prepare your fuel system by filling fuel tank and adding a
gasoline stabilizer. Use one of the commercially available
gasoline stabilizers following the manufacturer's instruc-
tions.

Remove the spark plugs, inject a few squirts of engine oil
into each cylinder and crank the engine 5-6 revolutions.
Reinstall spark plugs.

Inspect rear belt deflection. See

1.16 REAR BELT

DEFLECTION

Inspect rear belt and sprockets. See

1.15 REAR BELT

AND SPROCKETS

Inspect air cleaner filter. See

1.24 AIR CLEANER: XL

MODELS

1.25 AIR CLEANER: XR MODELS

Lubricate controls. See

1.23 CABLE AND CHASSIS

LUBRICATION

Inspect operation of all electrical equipment and switches.

Check tire inflation and inspect tires for wear and/or
damage. See

1.11 TIRES AND WHEELS

. If the motorcycle

will be stored for an extended period of time, securely
support the motorcycle under the frame so that all weight
is off the tires.

Be sure that brake fluid or other lubricants do not contact
brake pads or discs. Such contact can adversely affect
braking ability, which could cause loss of control, resulting
in death or serious injury. (00290a)

10. Wash painted and chrome-plated surfaces. Apply a light

film of oil to exposed unpainted surfaces.

Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)

Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

11. Remove battery from vehicle. Charge battery until the

correct voltage is obtained. Charge the battery every other
month if it is stored at temperatures below 60° F (16° C).
Charge battery once a month if it is stored at temperatures
above 60° F (16° C). See

1.17 BATTERY MAINTENANCE

Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)

12. If the motorcycle is to be covered, use a material that will

breathe, such as STORAGE COVER (Part No. 98716-
87A) or light canvas. Plastic materials that do not breathe
promote the formation of condensation, which leads to
corrosion.

REMOVAL FROM STORAGE

The clutch failing to disengage can cause loss of control,
which could result in death or serious injury. Prior to
starting after extended periods of storage, place transmis-
sion in gear and push vehicle back and forth several times
to assure proper clutch disengagement. (00075a)

HOME

1-88 2009 Sportster Service: Maintenance

1.35

TROUBLESHOOTING

GENERAL

The Troubleshooting section of this manual is a guide to
diagnose problems. Read the appropriate sections of this
manual before performing any work. Improper repair and/or
maintenance could result in death or serious injury.
(00528b)

The following check list of possible operating troubles and their
probable causes will be helpful in keeping a motorcycle in good
operating condition. More than one of these conditions may
be causing the trouble and all should be carefully checked.

NOTE

For further troubleshooting information, see the ELECTRICAL
DIAGNOSTIC MANUAL.

ENGINE

Starter Motor Does Not Operate or Does Not
Turn Engine Over

Engine run switch in OFF position.

Ignition switch not in IGNITION position.

Discharged battery, loose or corroded connections
(solenoid chatters).

Starter control circuit, relay, or solenoid faulty.

Electric starter shaft pinion gear not engaging or overrun-
ning clutch slipping.

TSM/TSSM/HFSM Bank Angle Sensor tripped and ignition
switch not cycled OFF then back to IGNITION position.

Security system activated.

Motorcycle in gear and clutch not pulled in.

Main fuse not in place.

10. Jiffy stand down and transmission in gear (HDI models).

Engine Turns Over But Does Not Start

Fuel tank empty.

Fuel filter clogged.

Plugged fuel injectors.

Discharged battery, loose or broken battery terminal con-
nections.

Fouled spark plugs.

Spark plug cables in bad condition and shorting, cable
connections loose or cables connected to incorrect cylin-
ders.

Ignition timing incorrect due to faulty coil, ECM or sensors
(TMAP, CKP) and/or TSM/TSSM/HFSM.

Bank Angle Sensor tripped and ignition/light key switch
not cycled OFF then back to IGNITION.

Damaged wire or loose wire connection at ignition coil,
battery or ECM connector.

10. Sticking or damaged valve(s) or wrong length push rod(s).

11. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

Starts Hard

Spark plugs in bad condition, have improper gap or are
partially fouled.

Spark plug cables in bad condition.

Battery nearly discharged.

Damaged wire or loose wire connection at battery terminal,
ignition coil or ECM connector.

Ignition not functioning properly (possible sensor failure).

Faulty ignition coil.

Fuel tank filler cap vent plugged or fuel line closed off
restricting fuel flow.

Water or dirt in fuel system.

Intake air leak.

10. Partially plugged fuel injectors.

11. Valves sticking.

12. Air cleaner EVAP flapper (if equipped) stuck close or

inoperative.

13. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

Starts But Runs Irregularly or Misses

Spark plugs in bad condition or partially fouled.

Spark plug cables in bad condition and shorting or leaking.

Spark plug gap too close or too wide.

Faulty ignition coil, ECM, or sensor (TMAP, CKP, ET or
O2).

Battery nearly discharged.

Damaged wire or loose connection at battery terminals,
ignition coil or ECM connector.

Intermittent short circuit due to damaged wire insulation.

Water or dirt in fuel system.

Fuel tank vent system plugged.

10. Air leak at intake manifold or air cleaner.

11. Partially plugged fuel injectors.

12. Damaged intake or exhaust valve(s).

13. Weak or broken valve springs.

14. Incorrect valve timing.

HOME

1-90 2009 Sportster Service: Maintenance

15. Air cleaner EVAP flapper (if equipped) stuck closed or

inoperative.

Spark Plug Fouls Repeatedly

Incorrect spark plug.

Piston rings badly worn or broken.

Fuel mixture too rich.

Valve guides or seals badly worn or damaged.

Pre-Ignition or Detonation (Knocks or Pings)

Excessive carbon deposit on piston head or in combustion
chamber.

Incorrect heat range spark plug.

Faulty spark plug(s).

Ignition timing advanced. ECM or sensors (CKP, ET or
TMAP) defective.

Fuel octane rating too low.

Intake manifold vacuum leak.

Check Engine Light Illuminates During
Operation

Fault detected. See the ELECTRICAL DIAGNOSTIC MANUAL
for this motorcycle.

Overheating

Insufficient oil supply or oil not circulating.

Insufficient air flow over engine.

Leaking valve(s).

Heavy carbon deposits.

Ignition timing retarded. ECM or sensor (CKP, TMAP)
defective.

Valve Train Noise

Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed.

Faulty hydraulic lifter(s).

Bent push rod(s).

Incorrect push rod length.

Cam(s), cam gear(s), or cam bushing(s) worn.

Rocker arm binding on shaft.

Valve sticking in guide.

Excessive Vibration

Stabilizer links worn or loose, or stabilizer link brackets
loose or broken.

Isolators worn or isolator bolts loose or broken.

Isolator mounting brackets (left side of vehicle) loose or
broken.

Rubber mounts loose or worn.

Rear fork pivot shaft fasteners loose.

Front engine mounting bolts loose.

Exhaust system binding or hitting frame.

Engine/transmission and rear wheel not aligned properly.

Broken frame.

10. Ignition timing advanced due to faulty sensor inputs (CKP,

TMAP)/poorly tuned engine.

11. Primary chain badly worn or links tight as a result of

insufficient lubrication or misalignment.

12. Wheels not aligned, rims bent, or tires worn or damaged.

13. Internal engine problem.

LUBRICATION SYSTEM

TOOL NAME

PART NUMBER

BLACK LIGHT LEAK DETECTOR

HD-35457

Oil Does Not Return To Oil Tank

Oil tank empty.

Oil pump gerotors damaged; oil pump not functioning.

Restricted oil hoses or fittings.

Restricted oil filter.

Engine Uses Too Much Oil Or Smokes
Excessively

Piston rings badly worn or broken.

Valve guide(s) or seal(s) worn or damaged.

Restricted oil filter.

Oil tank overfilled.

Restricted oil return hose to tank.

Restricted breather operation.

Plugged crankcase scavenge port.

Oil diluted with gasoline.

Engine Leaks Oil From Cases, Push Rods,
Hoses, Etc.

Loose parts.

Imperfect seal at gaskets, push rod cover, washers, etc.

NOTE

To aid locating leaks, use BLACK LIGHT LEAK
DETECTOR (Part No. HD-35457).

Restricted oil return hose to tank.

Restricted breather passage(s) to air cleaner.

Restricted oil filter.

Oil tank overfilled.

Porosity.

Low Oil Pressure

Oil tank underfilled.

Faulty low oil pressure switch.

HOME

2009 Sportster Service: Maintenance 1-91

Worn oil pump gerotor(s).

Worn pinion shaft drive gear.

Restricted feed hose from oil tank.

Restricted high-pressure feed hose to oil filter housing.

Oil diluted with gasoline.

Oil bypass plunger stuck open.

High Oil Pressure

Oil tank overfilled.

Restricted oil tank return hose.

Oil bypass plunger stuck closed.

ELECTRICAL SYSTEM

NOTE

For diagnostic information see the ELECTRICAL DIAGNOSTIC
MANUAL.

Alternator Does Not Charge

Voltage regulator module not grounded.

Engine ground wire loose or broken.

Faulty voltage regulator module.

Loose or broken wires in charging circuit.

Faulty stator and/or rotor.

Alternator Charge Rate Is Below Normal

Weak or damaged battery.

Loose connections.

Faulty voltage regulator module.

Faulty stator and/or rotor.

Speedometer Operates Erratically

Contaminated vehicle speed sensor (remove sensor and
clean off metal particles).

Loose connections.

TRANSMISSION

Shifts Hard

Clutch dragging slightly.

Transmission lubricant level too high.

Transmission lubricant too heavy (winter operation).

Shifter return spring (inside primary chaincase) bent or
broken.

Bent shifter rod.

Shifter forks sprung or damaged.

Corners worn off gear dogs and shifter dog rings.

Jumps Out Of Gear

Shifter engaging parts (inside transmission) badly worn
and rounded.

Shifter forks bent.

Shifter drum damaged/worn.

Damaged gears.

Clutch Slips

Clutch controls improperly adjusted.

Worn friction plates.

Insufficient clutch spring tension.

Clutch Drags Or Does Not Release

Lubricant level too high in primary chaincase.

Clutch controls improperly adjusted.

Clutch plates warped.

Insufficient clutch spring tension.

Primary chain badly misaligned or too tight.

Clutch Chatters

Friction plates or steel plates worn, warped or dragging.

HANDLING

Tires improperly inflated. See

1.11 TIRES AND WHEELS

Do not overinflate.

Loose wheel axle nuts. Tighten to recommended torque
specification.

Improper vehicle alignment: rear wheel out of alignment
with frame and front wheel.

Rims and tires out-of-true sideways.

Rims and tires out-of-round or eccentric with hub.

Loose spokes (models with laced wheels).

Irregular or peaked front tire tread wear.

Damaged tires or improper front-rear tire combination.

Tire and wheel unbalanced.

10. Steering head bearings improperly adjusted or pitted or

worn bearings and races.

11. Shock absorbers damaged or worn and not functioning

normally.

12. Heavy front end loading. Non-standard equipment on the

front end (such as heavy radio receivers, extra lighting
equipment, or luggage) tends to cause unstable handling.

13. Engine mounts and/or stabilizer links loose, worn or

damaged.

14. Rear fork pivot assembly: improperly tightened or

assembled, or loose, pitted or damaged pivot bearings.

BRAKES

Brake Does Not Hold Normally

Master cylinder reservoir low on fluid, system leaking or
pads worn.

Brake system contains air bubbles.

HOME

1-92 2009 Sportster Service: Maintenance

2.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installation

28.5-36.6 Nm

21-27 ft-lbs

Axle (front) pinch screw

2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation

55.6-65.1 Nm

41-48 in-lbs

Axle (front) pinch screw

2.4 WHEELS, Front Wheel

28.5-36.6 Nm

21-27 ft-lbs

Axle (front) pinch screw: XL Models

2.4 WHEELS, Front Wheel

55.6-65.1 Nm

41-48 ft-lbs

Axle (front) pinch screw: XR Models

2.4 WHEELS, General

81-88 Nm

60-65 ft-lbs

Axle nut, front

2.4 WHEELS, Front Wheel

81-88 Nm

60-65 ft-lbs

Axle nut, front

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installation

81-88 Nm

60-65 ft-lbs

Axle nut, front

2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation

81-88 Nm

60-65 ft-lbs

Axle nut, front

2.4 WHEELS, General

129-142 Nm

95-105 ft-lbs

Axle nut, rear

2.4 WHEELS, Rear Wheel

129-142 Nm

95-105 ft-lbs

Axle nut, rear

2.22 FRONT FORK: XR MODELS, Installation

6.8-7.9 Nm

60-70 in-lbs

Battery terminal bolts

2.24 BELT GUARD AND DEBRIS
DEFLECTOR, Belt Guard: XL Models

13.6-20.4 Nm

120-180 in-lbs

Belt guard screw, front (XL)

2.24 BELT GUARD AND DEBRIS
DEFLECTOR, Belt Guard: XR Models

8.1-10.8 Nm

72-96 in-lbs

Belt guard screw (XR), front

2.4 WHEELS, Rear Wheel

40.7-61.1 Nm

30-45 ft-lbs

Brake (rear) disc screw

2.18 BRAKE LINES, Rear Brake Line: XL Models

8.14-13.6 Nm

72-120 in-lbs

Brake (rear) line/switch tee bracket
screw

2.18 BRAKE LINES, Rear Brake Line: XR Models

1.9-2.5 Nm

17-22 in-lbs

Brake (rear) line/switch tee bracket
screw

2.12 FRONT BRAKE CALIPER: XR
MODELS, Assembly

16.9-24.5 Nm

12-18 ft-lbs

Brake bridge bolt, front caliper

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.11 FRONT BRAKE CALIPER: XL
MODELS, Assembly

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.12 FRONT BRAKE CALIPER: XR
MODELS, Assembly

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.18 BRAKE LINES, Front Brake Line: All Models

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.18 BRAKE LINES, Rear Brake Line: XL Models

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.18 BRAKE LINES, Rear Brake Line: XR Models

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.4 WHEELS, Front Wheel/Cast front wheel

21.7-32.6 Nm

16-24 ft-lbs

Brake disc mounting screw

2.4 WHEELS, Front Wheel/Cast front wheel

21.7-32.6 Nm

16-24 ft-lbs

Brake disc mounting screw

2.4 WHEELS, Front Wheel/Laced front wheel

21.7-32.6 Nm

16-24 ft-lbs

Brake disc mounting screw

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installation

38.0-51.6 Nm

28-38 ft-lbs

Brake front caliper mounting bolt

2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation

38.0-51.6 Nm

28-38 ft-lbs

Brake front caliper mounting bolt

HOME

2009 Sportster Service: Chassis 2-1

NOTES

TORQUE VALUE

FASTENER

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

1.0-2.0 Nm

9-17 in-lbs

Brake front cover master cylinder reser-
voir cover screw

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

12.2-14.9 Nm

108-132 in-lbs

Brake front master cylinder clamp screw

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installation

1.0-2.0 Nm

9-17 in-lbs

Brake front master cylinder reservoir
cover screw

2.18 BRAKE LINES, Rear Brake Line: XL Models

3.4-4.5 Nm

30-40 in-lbs

Brake hose clamp-to-battery tray screw

2.18 BRAKE LINES, Rear Brake Line: XL Models

3.4-4.5 Nm

30-40 in-lbs

Brake hose clamp-to-rear fork screw

2.18 BRAKE LINES, Rear Brake Line: XL Models

9.0-13.9 Nm

80-123 in-lbs

Brake lamp switch, rear

2.18 BRAKE LINES, Rear Brake Line: XR Models

9.0-13.9 Nm

80-123 in-lbs

Brake lamp switch, rear

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.16 REAR BRAKE CALIPER: XL
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.17 REAR BRAKE CALIPER: XR
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.18 BRAKE LINES, Front Brake Line: All Models

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.18 BRAKE LINES, Front Brake Line: All Models

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.18 BRAKE LINES, Rear Brake Line: XL Models

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.18 BRAKE LINES, Rear Brake Line: XR Models

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.18 BRAKE LINES, Front Brake Line: All Models

5.1-7.4 Nm

45-65 in-lbs

Brake line-to-front fork bracket clamp
screw

2.18 BRAKE LINES, Front Brake Line: All Models

13.6-19.0 Nm

120-168 in-lbs

Brake line-to-front fork lower bracket
clamp screw

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installing Brake Pads in Caliper

14.8-19.6 Nm

131-173 in-lbs

Brake pad pin

2.16 REAR BRAKE CALIPER: XL
MODELS, Installation

14.8-19.6 Nm

131-173 in-lbs

Brake pad pin

2.12 FRONT BRAKE CALIPER: XR
MODELS, Assembly

14.7-19.6 Nm

11-14 ft-lbs

Brake pad pin, front caliper

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installing Brake Pads in Caliper

2.0-2.9 Nm

18-25 in-lbs

Brake pad pin plug

2.16 REAR BRAKE CALIPER: XL
MODELS, Installation

2.0-2.9 Nm

18-25 in-lbs

Brake pad pin plug

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

10.9-17.6 Nm

96-156 in-lbs

Brake pedal clevis screw

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

10.9-17.6 Nm

96-156 in-lbs

Brake pedal clevis screw

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake rear master cylinder banjo bolt;
XL models

2.14 REAR BRAKE MASTER CYLINDER: XR
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake rear master cylinder banjo bolt;
XR models

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS, Installation

23.1-29.9 Nm

17-22 ft-lbs

Brake rear master cylinder mounting
bracket screw; XL models

HOME

2-2 2009 Sportster Service: Chassis

NOTES

TORQUE VALUE

FASTENER

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS, Installation

23.1-29.9 Nm

17-22 ft-lbs

Brake rear master cylinder mounting
bracket screw; XL models

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS, Installation

23.1-29.9 Nm

17-22 ft-lbs

Brake rear master cylinder mounting
screw; XL models

2.14 REAR BRAKE MASTER CYLINDER: XR
MODELS, Installation

8.1-10.9 Nm

72-96 in-lbs

Brake rear master cylinder mounting
screw; XR models

2.14 REAR BRAKE MASTER CYLINDER: XR
MODELS, Assembly

14.7-19.6 Nm

130-173 in-lbs

Brake rear master cylinder pushrod nut;
XR models

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS, Assembly

14.7-19.6 Nm

130-173 in-lbs

Brake rear master cylinder pushrod
shoulder nut

2.15 REAR BRAKE MASTER CYLINDER
RESERVOIR, Installation: XL Models

2.3-2.8 Nm

20-25 in-lbs

Brake rear master cylinder reservoir
mounting screw

2.25 REAR FORK, Installation

2.3-2.8 Nm

20-25 in-lbs

Brake rear master cylinder reservoir
mounting screw

2.15 REAR BRAKE MASTER CYLINDER
RESERVOIR, Installation: XR Models

4.1-6.8 Nm

36-60 in-lbs

Brake rear master cylinder reservoir
mounting screw; XR models

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

13.6-20.4 Nm

120-180 in-lbs

Brake rod-to-bell crank screw

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

13.6-20.4 Nm

120-180 in-lbs

Brake rod-to-bell crank screw

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

13.6-20.4 Nm

120-180 in-lbs

Brake rod-to-brake pedal screw

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

13.6-20.4 Nm

120-180 in-lbs

Brake rod-to-brake pedal screw

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

4.1-12.2 Nm

36-108 in-lbs

Clutch cable end fitting

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

0.9-1.5 Nm

8-13 in-lbs

Clutch lever anti-rattle spring screw

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

12.2-14.9 Nm

108-132 in-lbs

Clutch lever handlebar clamp screw

2.32 HANDLEBARS, Installation

12.2-14.9 Nm

108-132 in-lbs

Clutch lever handlebar clamp screw

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

10.9-13.6 Nm

96-120 in-lbs

Cylinder head exhaust port nut

2.24 BELT GUARD AND DEBRIS
DEFLECTOR, Debris Deflector: XL Models

4.1-6.8 Nm

36-60 in-lbs

Debris deflector screw (XL)

2.24 BELT GUARD AND DEBRIS
DEFLECTOR, Debris Deflector: XR Models

8.1-10.8 Nm

72-96 in-lbs

Debris deflector screw (XR)

2.28 FRONT ENGINE MOUNT/ISOLATOR, Install-
ation

81.4-95.0 Nm

60-70 ft-lbs

Engine mount (front) bolt

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket screw

2.21 FRONT FORK: XL MODELS, Installation

10.9-17.6 Nm

96-156 in-lbs

Fender (front) mounting screw

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

14.9-24.4 Nm

132-216 in-lbs

Fender (rear) mounting screw

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

HOME

2009 Sportster Service: Chassis 2-3

NOTES

TORQUE VALUE

FASTENER

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

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

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

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

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

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

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

2.21 FRONT FORK: XL MODELS, Installation

29.9-78.7 Nm

22-58 ft-lbs

Front fork slider tube cap

2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation

1.0-2.0 Nm

9-17 in-lbs

Front master cylinder cover screw

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

21.7-27.1 Nm

16-20 ft-lbs

Gear shift lever pinch screw

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

21.7-27.1 Nm

16-20 ft-lbs

Gear shift lever pinch screw

2.32 HANDLEBARS, Installation

0.9-1.4 Nm

8-12 in-lbs

Handlebar riser cover screw (XL
883C/XL 1200C)

2.32 HANDLEBARS, Installation

40.7-54.3 Nm

30-40 ft-lbs

Handlebar riser mounting bolt (XL
883C/XL 1200C)

2.30 THROTTLE CABLES: ALL
MODELS, Assembly and Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screw

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

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

2.32 HANDLEBARS, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screw

HOME

2-4 2009 Sportster Service: Chassis

NOTES

TORQUE VALUE

FASTENER

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)

2.4 WHEELS, Front Wheel/Cast front wheel

21.7-32.6 Nm

16-24 ft-lbs

Hub plate mounting screw

2.36 REAR FENDER: XR MODELS, Installation

8.1-13.6 Nm

72-120 in-lbs

Inner fender screw: 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

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

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

2.23 FORK STEM AND BRACKET
ASSEMBLY, Assembly and Installation

40.7-47.5 Nm

30-35 ft-lbs

Lower fork bracket pinch screw

2.32 HANDLEBARS, Installation

40.7-54.3 Nm

30-40 ft-lbs

Lower handlebar clamp bolts

2.17 REAR BRAKE CALIPER: XR
MODELS, Installation

40.7-61.0 Nm

30-45 ft-lbs

Lower shock absorber fastener

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)

2.25 REAR FORK, Installation

61-68 Nm

45-50 ft-lbs

Passenger footrest support bracket
screw

2.43 PASSENGER FOOTRESTS, XL Models

61-68 Nm

45-50 ft-lbs

Passenger footrest support bracket
screw

2.36 REAR FENDER: XR MODELS, Installation

4.1-6.8 Nm

36-60 in-lbs

Passenger pillion retainer post screw:
XR models

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

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

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

40.7-44.7 Nm

30-33 ft-lbs

Rear sprocket cover screw: XR models

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

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

61-68 Nm

45-50 ft-lbs

Rider footrest 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

HOME

2009 Sportster Service: Chassis 2-5

Harley Davidson Sportster Models 2009. Service Repair Manual - page 17