Harley Davidson Sportster Models 2009. Service Repair Manual

NOTES

TORQUE VALUE

FASTENER

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

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

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

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

13.6-20.3 Nm

120-180 in-lbs

Shift linkage fastener

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

24.4-29.9 Nm

18-22 ft-lbs

Shift pedal clevis screw

2.42 RIDER FOOT CONTROLS: XR
MODELS, Adjusting Shift Pedal

13.6-20.4 Nm

120-180 in-lbs

Shift rod screw (XR)

2.4 WHEELS, Rear Wheel

61-68 Nm

45-50 ft-lbs

Shock absorber mounting screw

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

61-68 Nm

45-50 ft-lbs

Shock absorber mounting screw

2.26 SHOCK ABSORBERS, Installation

61-68 Nm

45-50 ft-lbs

Shock absorber mounting screw

2.26 SHOCK ABSORBERS, Installation

61-68 Nm

45-50 ft-lbs

Shock absorber mounting screw

2.4 WHEELS, Sealed Wheel Bearings

21.7-32.6 Nm

16-24 ft-lbs

Single caliper cast front wheel hub plate
screw

2.5 WHEEL LACING: 16 INCH RIM, Procedure

6.2 Nm

55 in-lbs

Spoke nipple

2.6 WHEEL LACING: 19 INCH RIM, Procedure

6.2 Nm

55 in-lbs

Spoke nipple

2.7 WHEEL LACING: 21 INCH RIM, Procedure

6.2 Nm

55 in-lbs

Spoke nipple

2.8 TRUING LACED WHEELS, Radial Truing

6.2 Nm

55 in-lbs

Spoke nipple

2.4 WHEELS, Rear Wheel

108.0 Nm

80 ft-lbs

Sprocket (rear) mounting screw - FINAL
torque

2.4 WHEELS, Rear Wheel

81.3 Nm

60 ft-lbs

Sprocket (rear) mounting screw - INITIAL
torque

HOME

2-6 2009 Sportster Service: Chassis

NOTES

TORQUE VALUE

FASTENER

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

9.0-13.6 Nm

80-120 in-lbs

Sprocket cover screw: XL models

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

9.0-13.6 Nm

80-120 in-lbs

Sprocket cover screw: XL models

2.27 STABILIZER LINKS, Lower Front Stabilizer
Link

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (lower front) frame bracket
mounting screw

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (lower front) frame bracket
mounting screw

2.27 STABILIZER LINKS, Upper Front Stabilizer
Link

74.6-88.2 Nm

55-65 ft-lbs

Stabilizer link (upper front) engine
bracket mounting screw

2.27 STABILIZER LINKS, Upper Front Stabilizer
Link

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (upper front) frame bracket
mounting screw

2.28 FRONT ENGINE MOUNT/ISOLATOR, Install-
ation

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (upper front) frame bracket
mounting screw

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (upper front) frame bracket
mounting screw

2.27 STABILIZER LINKS, Upper Front Stabilizer
Link

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

2.27 STABILIZER LINKS, Lower Front Stabilizer
Link

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

2.27 STABILIZER LINKS, Rear Stabilizer Link

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

2.28 FRONT ENGINE MOUNT/ISOLATOR, Install-
ation

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

2.28 FRONT ENGINE MOUNT/ISOLATOR, Install-
ation

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

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

5.1-5.4 Nm

45-48 in-lbs

Tail lamp base mounting screw

2.36 REAR FENDER: XR MODELS, Installation

8.1-13.6 Nm

72-120 in-lbs

Tail section bolts: XR models

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

10.9-13.6 Nm

96-120 in-lbs

Turn signal (front) clamp screw

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

14.9-24.4 Nm

132-216 in-lbs

Turn signal (rear) stalk nut

2.32 HANDLEBARS, Installation

16.3-24.4 Nm

12-18 ft-lbs

Upper handlebar clamp screw, front

2.32 HANDLEBARS, Installation

16.3-24.4 Nm

12-18 ft-lbs

Upper handlebar clamp screw, front

2.32 HANDLEBARS, Installation

16.3-24.4 Nm

12-18 ft-lbs

Upper handlebar clamp screw, rear

2.32 HANDLEBARS, Installation

16.3-24.4 Nm

12-18 ft-lbs

Upper handlebar clamp screw, rear

2.19 TIRES, Installation

1.4-1.7 Nm

12-15 in-lbs

Valve stem nut

HOME

2009 Sportster Service: Chassis 2-7

2.2

SPECIFICATIONS

SPORTSTER SPECIFICATIONS

Chassis Specifications

Table 2-1. Dimensions: 2009 Sportster 883 Models

XL 883L

LOW

XL 883C

CUSTOM

XL 883

XL 883R

ITEM

IN.

1524.00

60.00

1534.16

60.40

1524.00

60.00

Wheel base

2263.14

89.10

2293.62

90.30

2288.54

90.10

Overall length

894.08

35.20

830.58

32.70

830.58

32.70

Overall width

99.06

3.90

111.76

4.40

142.24

5.60

Road clearance

1160.78

45.70

1160.78

45.70

1160.78

45.70

Overall height*

642.62

25.30

673.10

26.50

693.42

27.30

Saddle height**

*XL 883R overall height is 44.8 in. (1137.9 mm).
**With 180 lb. (81.7 kg) rider on seat.

Table 2-2. Dimensions: 2009 Sportster 1200 Models

XR 1200

XL 1200N

NIGHTSTER

XL 1200L

LOW

XL 1200R

ROADSTER

XL 1200C

CUSTOM

ITEM

IN.

1518.92

59.80

1524.00

60.00

1516.38

59.70

1524.00

60.00

1534.16

60.40

Wheel base

2169.16

85.40

2179.32

85.80

2263.14

89.10

2288.54

90.10

2293.62

90.30

Overall length

927.10

36.50

924.56

36.40

894.08

35.20

932.18

36.70

830.58

32.70

Overall width

147.32

5.80

99.06

3.90

111.76

4.40

142.24

5.60

111.76

4.40

Road clearance

1145.54

45.10

1107.44

43.60

1188.72

46.80

1249.68

49.20

1160.78

45.70

Overall height

741.68

29.20

642.62

25.30

668.02

26.30

713.74

28.10

673.10

26.50

Saddle height*

*With 180 lb. (81.7 kg) rider on seat.

Table 2-3. Weights: 2009 Sportster 883 Models

XL 883R

XL 883L

LOW

XL 883C

CUSTOM

XL 883

ITEM

LB.

257.64

568.00

255.37

563.00

256.28

565.00

255.37

563.00

Weight (as shipped
from factory)

453.59

1000.00

453.59

1000.00

453.59

1000.00

453.59

1000.00

GVWR

151.95

335.00

151.95

335.00

151.95

335.00

151.95

335.00

GAWR front

301.64

665.00

301.64

665.00

301.64

665.00

301.64

665.00

GAWR rear

HOME

2-8 2009 Sportster Service: Chassis

Table 2-4. Weights: 2009 Sportster 1200 Models

XR 1200

XL 1200N

NIGHTSTER

XL 1200L

LOW

XL 1200R

ROADSTER

XL 1200C

CUSTOM

ITEM

LB.

254.92

562.00

247.21

545.00

252.65

557.00

256.28

565.00

254.92

562.00

Weight (as shipped
from factory)

453.59

1000.00

453.59

1000.00

453.59

1000.00

453.59

1000.00

453.59

1000.00

GVWR

158.76

350.00

151.95

335.00

151.95

335.00

151.95

335.00

151.95

335.00

GAWR front

294.84

650.00

301.64

665.00

301.64

665.00

301.64

665.00

301.64

665.00

GAWR rear

Table 2-5. Capacities: 2009 Sportster 883 Models

XL 883L

LOW

XL 883C

CUSTOM

XL 883

XL 883R

ITEM

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

12.49

3.30 gal.

17.03

4.50 gal.

12.49

3.30 gal.

Fuel tank (total)

2.65

2.80 qt.

2.65

2.80 qt.

2.65

2.80 qt.

Oil tank with filter

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

Transmission (approximate)

3.03

0.80 gal.

3.79

1.00 gal.

3.03

0.80 gal.

Low fuel warning light on

Table 2-6. Capacities: 2009 Sportster 1200 Models

XR 1200

XL 1200N

NIGHTSTER

XL 1200L

LOW

XL 1200R

ROADSTER

XL 1200C

CUSTOM

ITEM

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

13.25

3.50 gal.

12.49

3.30 gal.

17.03

4.50 gal.

17.03

4.50 gal.

17.03

4.50 gal.

Fuel tank
(total)

2.65

2.80 qt.

2.65

2.80 qt.

2.65

2.80 qt.

2.65

2.80 qt.

2.65

2.80 qt.

Oil tank
with filter

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

Transmission
(approximate)

1.89

0.50 gal.

3.03

0.80 gal.

3.79

1.00 gal.

3.79

1.00 gal.

3.79

1.00 gal.

Low fuel warning
light on

Table 2-7. Brake Disc Specifications

SPECIFICATION

292

11.5

Diameter (front and rear)

5.08

0.200

Minimum thickness (front)

5.84

0.230

Minimum thickness (rear)

0.20

0.008

Maximum disc runout (front and rear)

Tire Specifications

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)

Tire sizes are molded on the sidewall. Refer to the tire fitment
tables below. Rim size and contour are cast or stamped into
the exterior surface of the rim.

Example: T19 x 2.15 MT DOT. "T" indicates that the rim con-
forms to Tire and Rim Association standards. The "19" is the

HOME

2009 Sportster Service: Chassis 2-9

normal diameter of the rim in inches, measured at the bead
seat diameter. The "2.15" is the width of the bead seat meas-
ured in inches. "MT" designates the rim contour. "DOT" means

that the rim meets Department of Transportation Federal Motor
Vehicle Safety Standards.

Table 2-8. Tire Fitment: Tubeless Cast Wheels

TIRE

RIM VALVE HOLE DIA.

RIM SIZE

AND CONTOUR

WHEEL SIZE

AND POSITION

SIZE

TYPE

100/90-19 57H

Dunlop D401F

8.46

0.33

T19 x 2.15 MT

19 in - Front (XL

models)

150/80B16 71H

Dunlop D401

T16 x 3.00 D

16 in - Rear (XL

models)

120/70 ZR18

Dunlop D209F

E18 x 3.5 MT

18 in - Front (XR

models)

180/55 ZR17

Dunlop D209

E17 x 5.5 M

17 in - Rear (XR

models)

Table 2-9. Tire Fitment: Tube Type Steel Laced Wheels

TIRE

TUBE SIZE

RIM SIZE

AND CONTOUR

WHEEL SIZE

AND POSITION

SIZE

TYPE

MH90-21 54H

Dunlop D402F

MH90-21

T21 x 2.15 TLA

21 in - Front

100/90-19 57H

Dunlop D401F

MJ90-19

T19 x 2.50 TLA

19 in - Front

150/80B16 71H

Dunlop D401

MT90-16

T16 x 3.00 D

16 in - Rear

Table 2-10. Tire Fitment: Tube Type Chrome Aluminum Profile Laced Wheels

TIRE

TUBE SIZE

RIM SIZE

AND CONTOUR

WHEEL SIZE

AND POSITION

SIZE

TYPE

MH90-21 54H

Dunlop D402F

MH90-21

T21 x 2.15 MT

21 in - Front

150/80B16 71H

Dunlop D401

MT90-16

T16 x 3.00 MT

16 in - Rear

Table 2-11. Tire Pressures: 2009 Sportster Models

TIRE PRESSURE (COLD)

MODEL

REAR

FRONT

kPa

PSI

kPa

PSI

248

206

XL models (solo rider)

275

206

XL models (rider and passenger)

262

248

XR models (solo rider)

290

248

XR 1200 (rider and passenger)

HOME

2-10 2009 Sportster Service: Chassis

2.3

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

VEHICLE IDENTIFICATION NUMBER (V.I.N.):
SPORTSTER MODELS

General

See

Figure 2-1

. The full 17-digit V.I.N. is stamped on the

steering head and printed on a label located on the right front
frame down tube.

See

Figure 2-2

. A unique 17-digit serial or Vehicle Identification

Number (V.I.N.) is found on each motorcycle. For a description
of each item in the V.I.N., refer to

Table 2-12

Abbreviated V.I.N.

An abbreviated V.I.N. is stamped on the left side of the crank-
case between the front and rear cylinders.

Example: CV39111000

See

Figure 2-2

for the complete V.I.N. for the same motorcycle

as it appears on the steering head.

NOTE

Always give the full 17-digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle.

*1HD1BJY136K111000*

om00848

Stamped V.I.N.

V.I.N. label

Figure 2-1. V.I.N. Locations: Sportster Models

1 HD 1 CV 3 1 3 9 K 111000

om00895

Figure 2-2. Typical Harley-Davidson V.I.N.: 2009 Sportster Models

Table 2-12. Harley-Davidson V.I.N. Breakdown: 2009 Sportster Models

POSSIBLE VALUES

DESCRIPTION

POSITION

1=Originally manufactured for sale within the United States

Market designation

5=Originally manufactured for sale outside of the United States

HD=Harley-Davidson

Manufacturer

1=Heavyweight motorcycle (901 cc or larger)

Motorcycle type

4=Middleweight motorcycle (351 cc to 900 cc)

See V.I.N. model table

Model

2=Evolution

883 cc air-cooled, fuel-injected

Engine type

3=Evolution

1200 cc air-cooled, fuel-injected

6=Evolution

1200 cc precision-cooled, fuel-injected

HOME

2009 Sportster Service: Chassis 2-11

Table 2-12. Harley-Davidson V.I.N. Breakdown: 2009 Sportster Models

POSSIBLE VALUES

DESCRIPTION

POSITION

1=Regular

Introduction date

2=Mid-year
3=California/regular
4=Cosmetic changes and/or special introductory date
5=California/cosmetic changes and/or special introductory date
6=California/mid-year

Can be 0-9 or X

V.I.N. check digit

9=2009

Model year

K=Kansas City, MO U.S.A.

Assembly plant

Varies

Sequential number

Table 2-13. V.I.N. Model Codes: 2009 Sportster Models

MODEL

CODE

MODEL

CODE

XL 1200R Sportster

1200 Roadster

XL 883 Sportster

883

XL 1200L Sportster

1200 Low

XL 883C Sportster

883 Custom

XL 1200N Sportster

1200 Nightster

™

XL 883L Sportster

883 Low

XR 1200 Sportster

1200

XL 883R Sportster

883R

XL 1200C Sportster

1200 Custom

HOME

2-12 2009 Sportster Service: Chassis

2.4

WHEELS

GENERAL

Good handling and maximum tire mileage are directly related
to the care of wheels and tires. Regularly inspect wheels and
tires for damage and wear. If handling problems occur, see

1.35 TROUBLESHOOTING

or refer to

Table 2-14

for a list of

probable causes.

Keep tires inflated to the recommended air pressure. Always
balance the wheel after replacing a tube or tire.

Do not inflate tire beyond maximum pressure as specified
on sidewall. Over inflated tires can blow out, which could
result in death or serious injury. (00027a)

Table 2-14. Wheel Service Chart

REMEDY

CHECK FOR

Tighten front axle nut to 60-65 ft-lbs (81-88 Nm). Tighten rear
axle nut to 95-105 ft-lbs (129-142 Nm).

Loose axle nuts.

Replace wheel hub bearings. See

2.4 WHEELS, Sealed Wheel

Bearings

Excessive side-play or radial (up-and-down) play in wheel hubs.

Tighten or replace spokes. See

2.8 TRUING LACED WHEELS

and

2.5 WHEEL LACING: 16 INCH RIM

2.6 WHEEL LACING:

19 INCH RIM

2.7 WHEEL LACING: 21 INCH RIM

Loose spokes.

Check rear wheel alignment as described in this section or repair
rear fork as described in

2.25 REAR FORK

Alignment of rear wheel in frame or with front wheel.

True wheels, replace rims or replace spokes. See

2.8 TRUING

LACED WHEELS

and

2.5 WHEEL LACING: 16 INCH RIM

2.6 WHEEL LACING: 19 INCH RIM

2.7 WHEEL LACING: 21

INCH RIM

Rims and tires out-of-true sideways; should not be more than
1/32 in. (0.76 mm).

Rims and tires out-of-round or eccentric with hub; should not
be more than 1/32 in. (0.76 mm).

Replace as described in

2.4 WHEELS

and

2.19 TIRES

Irregular or peaked front tire wear.

Inflate tires to correct pressure. See

2.2 SPECIFICATIONS

Correct tire inflation.

Static balance may be satisfactory if dynamic balancing facilities
are not available. However, dynamic balancing is strongly
recommended.

Correct tire and wheel balance.

Correct adjustment and replace pitted or worn bearings. See

2.23 FORK STEM AND BRACKET ASSEMBLY

Steering head bearings.

Check for leaks. See

2.21 FRONT FORK: XL MODELS

2.22 FRONT FORK: XR MODELS

Damper tubes.

Check damping action and mounting stud bushings. See

2.26 SHOCK ABSORBERS

Shock absorbers.

Check for looseness. See

2.25 REAR FORK

Rear fork bearings.

TROUBLESHOOTING

See

Figure 2-3

. Check tire inflation pressure at least once each

week. At the same time, inspect tire tread for punctures, cuts,
breaks and other damage. Repeat the inspection before road
trips.

HOME

2009 Sportster Service: Chassis 2-13

sm01774

Figure 2-3. Checking Tire Pressure

Be sure tires are properly inflated, balanced and have
adequate tread. Inspect your tires regularly and see a
Harley-Davidson dealer for replacements. Riding with
excessively worn, unbalanced or under-inflated tires can
adversely affect stability and handling, which could result
in death or serious injury. (00014a)

At regular intervals of 5000 miles (8000 km), or whenever
handling irregularities are noted, see

Table 2-14

for the

recommended service procedure.

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)

NOTES

Use the following guidelines when installing a new tire or
repairing a flat.

•

Always locate and eliminate the cause of the original tire
failure.

•

Do not patch or vulcanize a tire casing. These procedures
weaken the casing and increase the risk of a blowout.

•

Only patch an inner tube as an emergency measure.
Replace the damaged tube as soon as possible.

•

Be sure the inner tube is the correct size for the tire casing.
Any stretching or wrinkling within the casing will weaken
the tube and result in premature failure.

•

The use of tires other than those specified can adversely
affect handling resulting in death or serious injury.

•

Tires, tubes and wheels are critical safety items. Since
the servicing of these components requires special tools
and skills, Harley-Davidson recommends that you see
your dealer for these services.

FRONT WHEEL

Removal

Block motorcycle underneath frame so front wheel is raised
off the ground.

See

Figure 2-4

. Check wheel bearing end play.

Mount a magnetic base dial indicator on the brake
disc. Set the indicator contact point on the end of the
axle.

Move the wheel back as far as it will go. Holding the
wheel in position, zero the dial indicator gauge.

Move the wheel forward as far as it will go. Note the
reading of the dial indicator. The lateral movement or
end play must be less than 0.002 in. (0.05 mm).
Repeat the procedure to verify the reading.

If the end play is 0.002 in. (0.05 mm) or more, replace
the wheel bearings.

See

Figure 2-5

. Remove brake caliper mounting screws

(3). Slide caliper (4) off brake disc and secure caliper out
of the way.

NOTES

•

Do not operate the front brake lever with the front wheel
removed or the caliper pistons may be forced out.
Reseating the pistons requires disassembly of the caliper.

•

On models with dual disc brakes, remove both calipers.

Remove axle nut (1) and flat washer (2) from axle on left
side of vehicle.

See

Figure 2-6

. On right side of vehicle, loosen nut (4) on

pinch screw (1). Pull axle out of hub while supporting
wheel.

Remove spacer and front wheel assembly.

sm01778

Magnetic base

Brake disc

Axle

Dial indicator

Figure 2-4. Check Wheel Bearing End Play

HOME

2-14 2009 Sportster Service: Chassis

sm03350

Axle nut

Flat washer

Brake caliper mounting screws

Brake caliper

Figure 2-5. Left Side Front Wheel Mounting: (Laced Front

Wheel Shown)

sm03592

Pinch screw

Washer

Lockwasher

Nut

Axle

Figure 2-6. Right Side Front Wheel Mounting: Typical

(Laced Front Wheel Shown)

Disassembly: Cast Front Wheel

If necessary, remove tire. See

2.19 TIRES

NOTE

Label all components as they are removed so they may be
returned to their original locations.

See

Figure 2-9

. Remove bearing spacers (9, 11) from right

and left sides of wheel.

If necessary, remove five screws (1) and left side brake
disc (13).

If necessary, remove five screws and right side brake disc
(14) (dual front disc models) or hub plate (8) (single front
disc models).

If necessary, remove roller bearings (4) and hub spacer
(10). See

2.4 WHEELS, Sealed Wheel Bearings

Disassembly: Laced Front Wheel

See

Figure 2-10

. Remove spacers (9, 11) from right and

left sides of wheel.

If necessary, remove five screws (1) and brake disc (14).

If necessary, remove wheel bearings (4) and hub spacer
(10). See

2.4 WHEELS, Sealed Wheel Bearings

NOTE

If only rim is to be replaced, tape spokes together to hold pos-
ition on hub and remove spokes from rim. Install taped
hub/spoke assembly to new rim and tighten spokes. Then
remove tape and true wheels. See

2.6 WHEEL LACING: 19

INCH RIM

2.7 WHEEL LACING: 21 INCH RIM

. Then, see

2.8 TRUING LACED WHEELS

If it is necessary to disassemble wheel, loosen spoke
nipples and spokes (8) and slide each spoke out of hub
(12).

Cleaning and Inspection

Inspect all parts for damage or excessive wear.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

Inspect brake pads and disc(s). See

. Replace as necessary.

Assembly: Cast Front Wheel

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)

See

Figure 2-9

. Install hub spacer (10) and wheel bearings

(4) if removed. See

2.4 WHEELS, Sealed Wheel Bearings

HOME

2009 Sportster Service: Chassis 2-15

Single front disc models: If necessary, install hub plate
and brake disc as follows:

Install hub plate (8) on left side of wheel. Secure with
new screws and tighten in an alternating pattern to
16-24 ft-lbs (21.7-32.6 Nm).

Install brake disc (13). Secure with new screws and
tighten in an alternating pattern to 16-24 ft-lbs (21.7-
32.6 Nm).

Dual front disc models: If necessary, install brake discs
as follows:

Hold brake discs together, inboard sides facing each
other (minimum thickness and part number stampings
are on outboard side of brake disc).

XL Models: See

Figure 2-7

. Orient brake discs so

that bulb shaped end of each slot is on the leading
edge of the slot in the direction of rotation, as shown.
Note that the words "LEFT" and "RIGHT" will be loc-
ated on what appears to be the incorrect sides when
oriented this way. This is correct per Service Bulletin
M-1192A.

XR Models: See

Figure 2-8

. Orient brake discs so

that outer diameter of each slot is on the leading edge
in the direction of rotation, as shown. Note that the
words "LEFT" and "RIGHT" will be located on correct
sides when oriented this way.

Rotate one brake disc as necessary, until all vent
holes are aligned with those of the other brake disc.

Holding brake discs aligned, use a felt marking pen
or paint pen to draw a line across the edge of both
brake discs.

See

Figure 2-9

. Keeping the paint marks on the edge

of both discs aligned, install both brake discs onto
hub. Secure with new screws and tighten in an
alternating pattern to 16-24 ft-lbs (21.7-32.6 Nm).

Install spacers (9, 11) on right and left sides of wheel.

Verify that wheel is true. See

2.9 CHECKING CAST

WHEEL RUNOUT

Install tire, if removed. See

2.19 TIRES

Assembly: Laced Front Wheel

See

Figure 2-10

. Install hub spacer (10) and wheel bear-

ings (4) if removed. See

2.4 WHEELS, Sealed Wheel

Bearings

If hub (12) and rim (5 or 16) were disassembled, reas-
semble and true wheel. See

2.6 WHEEL LACING: 19

INCH RIM

2.7 WHEEL LACING: 21 INCH RIM

. Then

see

2.8 TRUING LACED WHEELS

Install brake disc (14). Secure with new screws and tighten
to 16-24 ft-lbs (21.7-32.6 Nm).

Install spacers (9, 11) on right and left sides of wheel.

Verify that wheel is true. See

2.8 TRUING LACED

WHEELS

Install tire, if removed. See

2.19 TIRES

sm03329

Incorrect

Correct

Direction of Rotation

Figure 2-7. Dual Rotor Orientation: XL Models (Left Side

Brake Disc Shown)

HOME

2-16 2009 Sportster Service: Chassis

sm01776

Bearing spacer, narrow

Screw (dual front disc models-10, all others-5)

10.

Washer

Hub spacer

11.

Bearing spacer, wide

Nut

12.

Roller bearing (2)

Front axle

13.

Brake disc L.H.

Valve cap

14.

Valve stem assembly with nut

Brake disc R.H. (dual front disc models only)

15.

Wheel assembly, XR models

Wheel assembly, 19 in., XL models

Hub plate (single front disc models only)

Figure 2-9. Cast Wheel Front (typical)

HOME

2-18 2009 Sportster Service: Chassis

sm01777

10.

Hub spacer

Screw (dual front disc models-10, all others-5)

11.

Washer

Bearing spacer, wide

12.

Wheel hub

Nut

13.

Roller bearing (2)

Front axle

14.

Brake disc L.H.

Rim, 19 in. or 21 in., standard

15.

Valve cap

Valve stem nut

16.

Rim, 21 in., profile

Spoke and nipple

17.

Wheel assembly, 19 in. or 21 in, standard

Wheel assembly, 21 in., profile rim

18.

Brake disc, R.H. (dual front disc models only)

Bearing spacer, narrow

Figure 2-10. Laced Front Wheel

HOME

2009 Sportster Service: Chassis 2-19

Installation

See

Figure 2-9

Figure 2-10

. Apply a light coat of ANTI-

SEIZE LUBRICANT to the axle (12 or 13), bearing (4)
bores, and hub spacer (10) bore.

Position wheel between forks. Verify that bearing spacers
(9, 11) on right and left side of wheel bearings are in pos-
ition.

See

Figure 2-6

. With pinch screw (1) loose, insert threaded

end of axle (5) through right side fork. Push axle through
fork and wheel hub until it begins to emerge from left side
of hub.

Push axle through left fork, until axle shoulder contacts
external bearing spacer on right fork side.

See

Figure 2-5

. Install flat washer (2) and axle nut (1) over

threaded end of axle. Insert screwdriver or steel rod
through hole in axle on right side of vehicle. While holding
axle stationary, tighten axle nut to 60-65 ft-lbs (81-88 Nm).

If servicing a vehicle with dual front brakes, align calipers
to brake discs as follows:

Make sure axle pinch screw nut is loose.

See

Figure 2-9

Figure 2-10

. Position right fork leg

against bearing spacer (9).

XL Models: Tighten axle pinch screw to 21-27 ft-lbs
(28.5-36.6 Nm).

XR Models: Tighten axle pinch screw to 41-48 ft-lbs
(55.6-65.1 Nm).

Install brake caliper(s). See

2.11 FRONT BRAKE CAL-

IPER: XL MODELS

2.12 FRONT BRAKE CALIPER:

XR MODELS

Check wheel bearing end play after tightening axle nut to
specified torque. Excessive end play can adversely affect
stability and handling. Insufficient end play can cause
bearing seizure. Either condition can cause loss of control,
which could result in death or serious injury. (00285a)

Check wheel bearing end play. See

2.4 WHEELS, Front

Wheel

Whenever a wheel is installed and before moving the
motorcycle, pump brakes to build brake system pressure.
Insufficient pressure can adversely affect brake perform-
ance, which could result in death or serious injury.
(00284a)

Pump brake lever to move pistons out until they contact
outside brake pad(s). Verify piston location against pad.

REAR WHEEL

TOOL NAME

PART NUMBER

FAT JACK

HD-45968

Removal

Secure motorcycle upright on a suitable lift. Raise rear
end of motorcycle high enough to permit wheel removal,
using a FAT JACK (Part No. HD-45968) (or similar lifting
device) underneath frame.

Check wheel bearing end play.

Mount a magnetic base dial indicator on the brake
disc. Set the indicator contact point on the end of the
axle.

Move the wheel back as far as it will go. Holding the
wheel in position, zero the dial indicator gauge.

If end play is 0.002 in. (0.05 mm) or more, remove
wheel and replace both wheel bearings.

XL Models: Remove rear muffler. See

4.15 EXHAUST

SYSTEM: XL MODELS

XL Models: Remove right lower shock absorber nut and
pull screw out slightly. This will help avoid damage to
sprocket when rear wheel is removed.

See

Figure 2-11

. Remove e-clip (2), axle nut (1) and

washer (3).

Loosen adjuster screws several turns to relieve belt ten-
sion.

Gently tap end of axle (4) with a soft hammer to loosen.
Pull axle free of rear fork assembly.

Slide wheel forward and slip belt off sprocket.

NOTE

It is not necessary to disassemble rear brake caliper in order
to remove rear wheel.

XR Models: Disengage brake hose from clamps on lower
side of rear fork. Carefully slide caliper and bracket
assembly forward to disengage from brake disk and boss
on rear fork. Support assembly from frame using rope or
bungee cord.

10. Remove spacers and roll rear wheel assembly back out

of fork.

11. Remove rear wheel assembly.

NOTE

Do not operate rear brake pedal with rear wheel removed or
caliper piston may be forced out of piston bore. Reseating
piston requires disassembly of caliper.

HOME

2-20 2009 Sportster Service: Chassis

sm03593

Axle nut

E-clip

Washer

Rear axle

Figure 2-11. Rear Wheel Mounting (typical)

Disassembly

If necessary, remove tire. See

2.19 TIRES

NOTES

•

Sportster models sold in the Japanese market are
equipped with rear wheel compensating sprockets. See

D.1 COMPENSATING SPROCKET

for the correct disas-

sembly and repair procedures.

•

Label all components as they are removed so they may
be returned to their original locations.

Cast or Disc wheel: see

Figure 2-12

. Laced wheel: see

Figure 2-13

Remove spacers (8, 9) from left and right sides of wheel.

If necessary, remove five screws (15) to detach rear brake
disc (10) from left side of wheel.

If necessary, remove five screws (2) and washers (4) to
detach rear sprocket (7) from right side of wheel.

If necessary, remove wheel bearings (6) and hub spacer
(14). See

2.4 WHEELS, Sealed Wheel Bearings

NOTE

Laced Wheel: if only rim is to be replaced, tape spokes
together to hold position on hub and remove spokes from rim.
Install taped hub/spoke assembly to new rim and tighten
spokes. See

2.5 WHEEL LACING: 16 INCH RIM

2.6 WHEEL

LACING: 19 INCH RIM

2.7 WHEEL LACING: 21 INCH RIM

Then true wheel. See

2.8 TRUING LACED WHEELS

Laced Wheel: see

Figure 2-13

. If it is necessary to disas-

semble wheel, loosen spoke nipples and spokes (19) and
slide each spoke out of hub (18).

Cleaning and Inspection

Inspect all parts for damage or excessive wear.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

Inspect brake pads and disc. See

1.9 BRAKE PADS AND

DISCS: XL MODELS

1.10 BRAKE PADS AND DISCS:

XR MODELS

Inspect rear belt and sprocket. See

1.15 REAR BELT AND

SPROCKETS

Assembly

Laced Wheel: if wheel was disassembled, reassemble
hub, rim, spokes and nipples, and tighten spokes. See

2.5 WHEEL LACING: 16 INCH RIM

2.6 WHEEL LACING:

19 INCH RIM

2.7 WHEEL LACING: 21 INCH RIM

Cast or disc wheel: see

Figure 2-12

. Laced wheel: see

Figure 2-13

Install hub spacer (14) and wheel bearings (6), if removed.
See

2.4 WHEELS, Sealed Wheel Bearings

If brake disc (10) was removed, install brake disc on valve
stem side of wheel. Secure with new screws and tighten
to 30-45 ft-lbs (40.7-61.1 Nm).

NOTE

Sportster models sold in the Japanese market are equipped
with rear wheel compensating sprockets. See

D.1 COMPENS-

ATING SPROCKET

for the correct assembly/installation pro-

cedure.

If rear sprocket (7) was removed, install sprocket on side
of wheel opposite valve stem.

Secure with new screws and washers (4). Tighten to
60 ft-lbs (81.3 Nm).

Loosen each screw 180° and retighten to 80 ft-lbs
(108.0 Nm).

Verify that wheel assembly is true. See

2.8 TRUING

LACED WHEELS

2.9 CHECKING CAST WHEEL

RUNOUT

Install tire, if removed. See

2.19 TIRES

HOME

2009 Sportster Service: Chassis 2-21

Harley Davidson Sportster Models 2009. Service Repair Manual - page 18