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Harley Davidson Sportster Models 2009. Service Repair Manual - page 19

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10.

Brake disc

E-clip

11.

Screw (5)

Valve cap

12.

Axle

Washer

13.

Washer (5)

Valve stem

14.

Hub spacer

Axle nut

15.

Roller bearing (2)

Screw (5)

16.

Wheel assembly, disc: XL models

Sprocket

17.

Spacer, wide

Wheel assembly, cast: XL models

18.

Wheel assembly, cast: XR models

Spacer, narrow

Figure 2-12. Cast or Disc Rear Wheel

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2-22 2009 Sportster Service: Chassis

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12.

Axle

E-clip

13.

Screw (5)

Valve stem nut

14.

Hub spacer

Spacer

15.

Washer (5)

Brake disc screw (5)

16.

Rim, standard (all except XL 883C/XL 1200C)

Axle nut

17.

Roller bearing (2)

Wheel assembly, 16 in., standard rim

18.

Hub

Sprocket

19.

Spacer, wide

Spoke and nipple (40)

20.

Rim, profile (XL 883C/XL 1200C only)

Spacer, narrow

10.

21.

Brake disc

Wheel assembly, 16 in., profile rim

11. Valve cap

Figure 2-13. Laced Rear Wheel

HOME

2009 Sportster Service: Chassis 2-23

Installation

See

Figure 2-12

Figure 2-13

. Apply a light coat of ANTI-

SEIZE LUBRICANT to the axle (12), bearing (6) bores,
and hub spacer (14) bore.

Place wheel centrally in the rear fork assembly. Engage
the brake disc in the caliper on XL models.

XR Models: With the wheel as far forward as possible,
install the caliper/bracket assembly in place, engaging the
brake disk and the boss on the rear fork.

Slide wheel forward and slip belt over sprocket and then
slide the wheel back.

Position sprocket side spacer (8) between wheel and rear
fork.

Insert axle (12) through right side of rear fork and right
side axle adjuster, sprocket side spacer (8), wheel
assembly, disc side spacer (9), rear caliper bracket, and
left side of rear fork and left side axle adjuster.

Install washer (3) and axle nut (5) on left end of axle. Do
not tighten nut at this time.

XL Models: Slide right lower shock absorber screw back
in place. Install nut and tighten to 45-50 ft-lbs (61-68 Nm).

NOTE

If rear brake caliper was disassembled or removed, see

2.16 REAR BRAKE CALIPER: XL MODELS

2.17 REAR

BRAKE CALIPER: XR MODELS

for the proper assembly and

installation procedure.

Check for proper belt tension and rear wheel alignment.
See

1.16 REAR BELT DEFLECTION

Do not exceed specified torque when tightening axle nut.
Exceeding torque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious
injury. (00408e)

10. Tighten axle nut to 95-105 ft-lbs (129-142 Nm). Install e-

clip.

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)

11. Check wheel bearing end play. See

2.4 WHEELS, Rear

Wheel

12. XL Models: Install rear muffler. See

4.15 EXHAUST

SYSTEM: XL MODELS

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)

13. Pump brake pedal to move piston out until it contacts

outside brake pad. Verify piston location against pad.

SEALED WHEEL BEARINGS

TOOL NAME

PART NUMBER

WHEEL BEARING
INSTALLER/REMOVER

HD-44060-B

Inspection

Inspect the play of the wheel bearings by finger while they
are in the wheel. Rotate the inner bearing race and check
for abnormal noise. Make sure bearing rotates smoothly.

Check wheel bearings and axle spacers for wear and
corrosion. Excessive play or roughness indicates worn
bearings. Replace bearings in sets only.

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2-24 2009 Sportster Service: Chassis

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Figure 2-14. Wheel Bearing Remover/Installer (HD-44060-B) (See Table)

Table 2-15. HD-44060-B Wheel Bearing Remover/Installer

PART NO.

DESCRIPTION

NO.

HD-44060-5

Bridge

12547

Steel ball

HD-44060-4

6 in. forcing screw

222413

1/2-20 UNF nut

12004

Washer

280856

11 in. forcing screw

HD-44060-1

Support plate

HD-44060-8

Pilot, 1 in. and 25 mm

HD-44060-6

Pilot, 3/4 in.

HD-44060-7A

Collet, 1 in.

HD-44060-3A

Collet, 3/4 in.

J-23444-A

Thread lubricant

217801

Bearing

215654

1/2-13 UNC nut

HD-44060-10

Collet, 25 mm

HD-44060-11

Collet, 25 mm (ABS only)

Removal

If not already done, remove wheel from motorcycle. See

2.4 WHEELS

. On models with a single front brake caliper,

remove hub plate from wheel on side opposite front brake
disc.

NOTE

See

Figure 2-15

. Some wheel hubs may not provide adequate

support for the puller bridge. In these cases, center a used
brake disc over the hub to support the puller bridge while
removing the bearing.

HOME

2009 Sportster Service: Chassis 2-25

SM03870

Figure 2-15. Brake Disk as Puller Aid

See

Figure 2-16

. Obtain WHEEL BEARING

INSTALLER/REMOVER (Part No. HD-44060-B) and
assemble.

Sparingly apply graphite lubricant to threads of forcing
screw (1) for prolonged service life and smooth
operation.

Install nut (2), washer (3) and Nice bearing (4) on
screw. Insert assembly through hole in bridge (5).

Drop ball bearing inside collet (6). Fasten collet and
ball bearing to forcing screw.

Hold end of forcing screw and turn collet to expand edges
of collet.

See

Figure 2-17

. When expanded collet has gripped

bearing edges, hold end of forcing screw (1) and turn the
nut (2) to remove bearing from wheel.

Remove spacer from inside wheel hub.

Repeat procedure for opposite side bearing. Discard both
bearings upon removal.

sm01685

Forcing screw

Nut

Washer

Nice bearing

Bridge

Collet with ball bearing inside

Figure 2-16. Wheel Bearing Removal Tool

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Forcing screw

Nut

Figure 2-17. Removing Bearing

HOME

2-26 2009 Sportster Service: Chassis

Installation

NOTES

•

When installing wheel bearings, use specialty tool WHEEL
BEARING INSTALLER/REMOVER (Part No. HD-44060-
B).

•

Always install first bearing on primary brake disc side. If
front wheel has two brake discs, install bearing on the left
side first.

See

Figure 2-14

. Obtain WHEEL BEARING

INSTALLER/REMOVER (Part No. HD-44060-B) and
assemble.

Sparingly apply graphite lubricant to threads of
threaded rod (6) for prolonged service life and smooth
operation.

See

Figure 2-18

. Place threaded rod (1) through

support plate (2). Insert assembly through wheel.

See

Figure 2-19

. Place new bearing on rod (1) with

lettered side facing out.

Install pilot (5), Nice bearing (4), washer (3) and nut
(2) over rod.

Hold hex end of threaded rod and turn nut to install wheel
bearing. Bearing is fully seated when nut can no longer
be turned. Remove tool.

Install spacer inside wheel hub.

Reverse tool and install opposite side wheel bearing.

On cast front wheels with single brake caliper, apply two
drops of LOCTITE THREADLOCKER 243 to hub plate
mounting screws. Install hub plate opposite brake disc
and secure with screws. Tighten to 16-24 ft-lbs (21.7-32.6
Nm).

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Threaded rod

Support plate

Figure 2-18. Assembling Installation Tool

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Threaded rod

Nut

Washer

Nice bearing

Pilot

Wheel bearing

Figure 2-19. Installing Bearing

HOME

2009 Sportster Service: Chassis 2-27

2.5

WHEEL LACING: 16 INCH RIM

GENERAL

NOTES

•

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. Then
remove tape and true wheels.

•

Do not install incorrect spokes or spoke nipples on rim.

See

Figure 2-20

. Measure spoke length (distance "A"). To

determine correct spoke length for type of rim used, refer to

Table 2-16

sm02258

Figure 2-20. Measuring Spoke Length

Table 2-16. Rim Spoke Length

IN.

RIM

170.4-171.5

6.71-6.75

Steel laced

173.7-174.8

6.84-6.88

Chrome aluminum
profile laced

sm02259

Narrow flange (brake side)

Wide flange (sprocket side)

Figure 2-21. Rim, Hub and Spoke Nipple

PROCEDURE

NOTE

The primary brake disc side of the hub can be identified by
having one or two grooves cut into the disc mounting surface.

See

Figure 2-22

. Place hub on table with primary brake

disc side up. Insert a spoke in each hole of lower row as
shown in the figure. Angle spokes clockwise.

sm02261

Figure 2-22. Hub: Primary Brake Disc Side Up

See

Figure 2-23

. Center rim over hub assembly with valve

stem hole facing upward.

Using any lower row spoke, place first spoke into rim hole
to left of valve stem hole on upper half of rim centerline.

sm02262

Figure 2-23. Brake Side Up: Start First Spoke of Bottom

Row

See

Figure 2-24

. Install remaining lower row spokes, one

in every fourth hole.

HOME

2-28 2009 Sportster Service: Chassis

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Figure 2-24. Brake Side Up: Bottom Row of Spokes Laced

See

Figure 2-25

. Place first upper row spoke into hub as

shown. Angle spoke counterclockwise, crossing four
lower row spokes. Spoke must enter hole to left of valve
stem hole.

sm02263

Figure 2-25. Brake Side Up: Start First Spoke of Top Row

See

Figure 2-26

. Install remaining nine upper row spokes

into every fourth remaining hole above rim centerline. This
completes spoke installation on brake disc side.

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Figure 2-26. Brake Side Up: Top Row of Spokes Laced

See

Figure 2-27

. Turn wheel assembly over so primary

brake disk side faces down. Place any lower row spoke
into hub. Angle spoke clockwise and place into rim hole
angled to accept it.

sm02265

Figure 2-27. Sprocket Side Up: Start First Spoke of Bottom

Row

See

Figure 2-28

. Place remaining nine lower row spokes,

angled clockwise, into hub and rim.

HOME

2009 Sportster Service: Chassis 2-29

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Figure 2-28. Sprocket Side Up: Bottom Row of Spokes

Laced

See

Figure 2-29

. Insert any upper row spoke into hub and

angle spoke counterclockwise. Place spoke into appro-
priate rim hole.

sm02267

Figure 2-29. Sprocket Side Up: Start First Spoke of Top

Row

10. See

Figure 2-30

. Install remaining nine upper row spokes.

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Figure 2-30. Wheel Completely Laced

11. Tighten spoke nipples to specification listed in

Table 2-17

12. True wheel. See

2.8 TRUING LACED WHEELS

Table 2-17. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

55 in-lbs (6.2 Nm)

All

HOME

2-30 2009 Sportster Service: Chassis

2.6

WHEEL LACING: 19 INCH RIM

PROCEDURE

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.

Divide spokes into two groups.

Inner spokes have long heads.

Outer spokes have short heads.

Lubricate spoke threads and nipple shoulders with tire
mounting lubricant.

NOTE

The primary brake disc side of the hub can be identified by
having one or two grooves cut into the disc mounting surface.

See

Figure 2-31

. Place hub on bench with the primary

brake disc side up. Insert one outer spoke (short head)
into any bottom flange hole and swing it clockwise. Insert
an inner spoke (long head) in the next hole to the left of
the outer spoke. Swing the inner spoke counterclockwise
over the outer spoke.

Find the hole in the upper flange directly above the two
spokes just inserted. This hole uses a long head inner
spoke. Insert inner spoke into the hole on the upper flange
that directly bisects the two spokes in the bottom flange.
Insert all remaining spokes in upper flange alternating the
inner and outer spokes.

After one flange side is completed flip wheel hub upside
down and repeat to finish other flange.

See

Figure 2-32

. With all forty spokes inserted in hub,

group all spokes on top flange into two bundles. Secure
each group with throttle grips to keep the spokes together.

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Outer spoke (short head)

Inner spoke (long head)

Figure 2-31. Lacing 19 Inch Wheel Hub

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Figure 2-32. Bundling Top Spokes

Swing all bottom flange outer spokes (short head) clock-
wise.

Swing the inner spokes (long head) counterclockwise,
crossing over the outer spokes (short head).

Angle all spokes as far as they will go without overlapping
the next LIKE spoke. For instance, swing an inner spoke
(long head) counter clockwise across four spokes as far
as it will go before crossing another inner spoke (laced in
a cross-four pattern).

NOTES

•

All inside spokes lay over all outside spokes.

•

See

Figure 2-33

. The valve stem hole is centered of the

rim; you do not have to worry about choosing the correct
relationship between the rim and the hub.

10. Center the rim over the hub assembly.

NOTE

It is recommended that you lace the first spoke next to the
valve stem hole. When lacing your first spoke, place spoke
nipples through several rim holes to determine the correct
lacing direction. Only one spoke will fit into the spoke nipple
correctly. When connecting the spoke to the spoke nipple,
finger tighten two to three threads.

11. Straighten any spokes that were accidentally bumped or

moved on the bottom flange.

12. Work with the bottom flange of outer spokes (short head)

first.

13. See

Figure 2-34

. Using the spoke alignment method dis-

cussed previously, locate a hole pointing downward and
outward toward the bottom flange of outer spokes (short
head).

Verify outer spoke (short head) reaches the spoke
nipple and secure spoke loosely by hand. Skip three
rim holes and repeat lacing. Follow pattern to com-
plete bottom flange outer spokes (short head).

See

Figure 2-35

. Once you have completed lacing

the bottom row of outer spokes (short head) double
check for three empty holes in between each spoke.

HOME

2009 Sportster Service: Chassis 2-31

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Figure 2-33. Valve Stem Hole Location

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Figure 2-34. Beginning Spoke: Bottom Flange Outer

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Figure 2-35. Completed Spokes: Bottom Flange Outer

14. Work with bottom flange inner spokes (long head) next.

Choose a beginning spoke closest to the valve stem hole.

See

Figure 2-36

. Each inner spoke (long head)

crosses four outer spokes (short head).

See

Figure 2-37

. Verify inner spoke reaches spoke

nipple and secure spoke loosely by hand. Skip every
other hole and repeat lacing. Follow pattern to com-
plete bottom row inner spokes (long head).

15. See

Figure 2-38

. Undo each top bundle and fan the spokes

out (in a starburst pattern) around the top rim edge.

sm02250

Figure 2-36. Beginning Spoke: Bottom Flange Inner

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Figure 2-37. Completed Spokes: Bottom Flange Inner

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Figure 2-38. Fanning Top Flange Spokes

16. See

Figure 2-39

. Point all the top flange inner spokes (long

head) clockwise one at a time leaving the outer spokes
(short head) resting on the rim.

HOME

2-32 2009 Sportster Service: Chassis

NOTE

Do not knock outer spokes (short head) under inner spokes
(long head) or they will be trapped underneath the inner row
of spokes.

17. Using the spoke alignment method discussed previously,

choose a beginning spoke closest to the valve stem hole.
Start with top flange inner spokes (long head) first.

See

Figure 2-40

. Verify spoke reaches spoke nipple

and secure spoke by hand. Follow pattern to complete
top flange inner spokes (long head).

See

Figure 2-41

. Once you have completed the top

flange of inner spokes (long head) double check for
one empty hole after every third spoke.

sm02253

Figure 2-39. Setting Top Flange Inner Spokes

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Figure 2-40. Beginning Spoke: Top Flange Inner

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Figure 2-41. Completed Spokes: Top Flange Inner

18. See

Figure 2-42

. Finish with top flange outer spokes (short

head). Point the top flange outer spokes (short head)
counterclockwise and make sure each one crosses four
inner spokes before securing it to the rim.

19. See

Figure 2-43

. Verify spoke reaches spoke nipple and

secure spoke by hand. Follow pattern to complete top
flange outer spokes (short head).

20. Tighten spoke nipples to specification listed in

Table 2-18

21. True the wheel. See

2.8 TRUING LACED WHEELS

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Figure 2-42. Beginning Spoke: Top Flange Outer

HOME

2009 Sportster Service: Chassis 2-33

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Figure 2-43. Completed Spokes: Top Flange Outer

Table 2-18. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

55 in-lbs (6.2 Nm)

All

HOME

2-34 2009 Sportster Service: Chassis

2.7

WHEEL LACING: 21 INCH RIM

GENERAL

NOTE

Do not install incorrect spokes or spoke nipples on rim. Using
incorrect spokes can result in improper thread engagement
which could result in damage to rim, tubes or tire.

See

Figure 2-44

. Measure distance "A" to determine spoke

length. Refer to

Table 2-19

to determine correct spoke length

for type of rim used.

Table 2-19. 21 Inch Rim Spoke Length

IN.

RIM

239.3-240.3

9.42-9.46

Steel laced

241.8-242.8

9.52-9.56

Chrome aluminum profile
laced

sm02258

Figure 2-44. Measuring Spoke Length

PROCEDURE

Divide spokes into two groups.

Inner spokes have long heads.

Outer spokes have short heads.

NOTE

See

Figure 2-45

. The spoke holes in the 21 inch wheel hub

are staggered, alternating between inner holes (nearer hub
center) and outer holes (nearer hub edge).

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Outer spoke hole

Inner spoke hole

Figure 2-45. Spoke Hole Pattern

Lubricate spoke threads and nipple shoulders with tire
mounting lubricant.

See

Figure 2-46

. Place hub on bench with the brake disc

side up. Insert one outer spoke (short-head) into an outer
top flange hole and swing it counterclockwise. Insert an
inner spoke (long-head) in the next hole to the right of the
outer spoke. Swing the inner spoke clockwise under the
outer spoke.

In the same way, insert all remaining spokes in brake-side
flange alternating inner and outer spokes.

After brake-side flange is completed flip wheel hub over
and repeat procedure on other flange.

sm01787

Outer spoke hole

Outer spoke (short head)

Figure 2-46. Lacing 21 Inch Wheel Hub

See

Figure 2-47

. With all forty spokes inserted in hub,

group all spokes on top flange into two bundles. Secure
each group with throttle grips to keep the spokes together.

HOME

2009 Sportster Service: Chassis 2-35

sm01788

Figure 2-47. Bundling Top Spokes

Make sure all spokes on brake-side flange are still
arranged properly and pointing in the right direction:

Swing all outer spokes (short-head) clockwise.

Swing the inner spokes (long-head) counterclockwise,
crossing over the outer spokes (short-head).

Angle all spokes as far as they will go without overlap-
ping the next LIKE spoke. For instance, swing an
inner spoke (long-head) counterclockwise across four
spokes as far as it will go before crossing another
inner spoke (laced in a cross-four pattern).

NOTES

•

All inside spokes lay over all outside spokes.

•

See

Figure 2-48

. The valve stem hole is centered on the

rim; you do not have to worry about choosing the correct
relationship between the rim and the hub.

Center the rim over the hub assembly.

sm01789

Figure 2-48. Valve Stem Hole Location

NOTE

Straighten any spokes that were accidentally bumped or
moved on the bottom flange.

10. Work with the bottom flange of outer spokes (short-head)

first. See

Figure 2-49

. Using the spoke alignment method

discussed previously, locate a spoke hole in the rim

pointing downward and outward toward the bottom flange
of outer spokes (short-head).

Verify outer spoke (short-head) reaches the spoke
nipple and secure spoke loosely by hand. Skip three
rim holes and repeat lacing. Follow pattern to com-
plete bottom flange outer spokes (short-head).

See

Figure 2-50

. Once you have completed lacing

the bottom row of outer spokes (short-head) double
check for three empty holes in between each spoke.

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Figure 2-49. Beginning Spoke-Bottom Flange Outer

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Figure 2-50. Completed Spokes-Bottom Flange Outer

11. Work with bottom flange inner spokes (long-head) next.

Choose a beginning spoke closest to the valve stem hole.

See

Figure 2-51