Harley Davidson Sportster Models 2009. Service Repair Manual

sm01459

Rear brake caliper

Caliper mounting bracket

Caliper bushing boot

Caliper pin boot

Bolt pin (caliper)

Bolt pin (mounting bracket)

Tapered shoulder

Boot lip

Figure 2-127. Assembling Rear Brake Caliper to Mounting

Bracket

ASSEMBLY

NOTE

Use ONLY KS62F assembly grease for lubrication. Use of
D.O.T. 4 brake fluid will result in increased brake pedal travel.

Lubricate the following parts prior to assembly using a
light coat of KS62F assembly grease from the service
parts kit. All other surfaces must be dry for assembly.

Nose radius of piston. See

Figure 2-128

All surfaces of piston seal and dust seal.

NOTE

A damaged piston bore will leak when reassembled. Do not
use metal objects to remove or install components in piston
bore. Prevent damage to bore by only using a wooden toothpick
when servicing caliper.

See

Figure 2-125

. Install a new piston seal (3) and a new

dust seal (2) into piston bore.

Carefully insert piston by hand, nose radius first (see

Figure 2-122

), into caliper bore. If installation shows res-

istance, remove piston and check that seals are properly
installed and fully seated in grooves.

See

Figure 2-122

. Install bleeder valve (12) on caliper

housing if removed. Do not tighten bleeder valve at this
time.

See

Figure 2-129

. Place caliper and mounting bracket

assembly on workbench as shown. Install pad spring in
channel. Press firmly into place.

sm01456

Figure 2-128. Piston Nose Radius

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2-86 2009 Sportster Service: Chassis

sm01432

Figure 2-129. Rear Caliper Pad Spring

INSTALLATION

See

Figure 2-130

. Before installing caliper, make sure that

retainer clip is properly installed on mounting bracket.

See

Figure 2-122

. Place rear caliper assembly (6) onto

mounting bracket (1), being careful not to pinch or roll
boots over.

Install rear brake caliper and mounting bracket assembly
onto vehicle.

NOTE

Brake caliper housing has a positive stop for banjo fitting. When
tightening banjo bolt into brake caliper in the next step, rotate
banjo fitting clockwise until it contacts positive stop.

See

Figure 2-131

. Position a new washer (2) on each side

of hydraulic brake line (3) banjo fitting. Insert banjo bolt
(1) through washers and fitting. Thread bolt into caliper
housing. Tighten to 20-25 ft-lbs (27.1-33.9 Nm).

NOTE

The rear brake caliper does NOT use the same exact brake
pad set as the front left and front right (not present on all
models) calipers.

See

Figure 2-132

. Insert brake pads (1) into caliper with

friction material on pad facing brake disc. Curved portion
of pad fits into recessed area of caliper. Make sure brake
pad front mounting tab (2) fits into slot (5) in caliper
mounting bracket (4).

See

Figure 2-122

. Press brake pads (15) tightly up against

pad spring (2) and install pad pin (10). Tighten to 131-173
in-lbs (14.8-19.6 Nm).

NOTES

If pad pin does not fit, check the following:

•

You are using a set of pads, not two identical pads.

•

Pad spring orientation must match

Figure 2-129

•

See

Figure 2-132

. Pad front mounting tabs (2) must be

fully seated in mounting bracket slot (5).

•

Pads must be pushed tight up against pad spring before
pad pin is installed.

See

Figure 2-122

. Install pad pin plug (9). Tighten to 18-25

in-lbs (2.0-2.9 Nm).

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)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTES

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.

•

See

Figure 2-133

. Reservoir cover (2) may be removed

from rear brake master cylinder reservoir (1) to more easily
verify fluid level in reservoir.

See

Figure 2-133

. If desired, remove reservoir cover: grasp

cover (2) and gently pull straight out from reservoir (1).

Remove rear brake master cylinder reservoir cap (5). Add
HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID to reservoir
until fluid reaches upper fluid level (3). Do not overfill
reservoir. Do not reuse brake fluid.

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

10. Bleed brake system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

A plugged or covered relief port can cause brake drag or
lock-up, which could lead to loss of control, resulting in
death or serious injury. (00288a)

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2009 Sportster Service: Chassis 2-87

11. Verify proper operation of master cylinder relief port.

Press against rear brake caliper to push caliper piston
back into its bore. This pushes brake fluid back
through master cylinder and verifies that relief port is
not plugged.

Pump brake pedal until caliper piston pushes pads
against disc and pressure is returned to brake system.

12. Add HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID to

reservoir until fluid reaches upper fluid level.

13. If reservoir cover was removed, install cover on reservoir.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

14. Test brake system.

Turn ignition switch ON. Pump brake pedal to verify
operation of brake lamp.

Test ride motorcycle at low speed. If brakes feel
spongy, bleed system again. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

sm01460

Figure 2-130. Retainer Clip

sm03594

Banjo bolt

Washer (2)

Rear brake line

Brake caliper

Caliper mounting bracket

Damper

Figure 2-131. Rear Caliper Assembly

sm01462

Brake pad

Front mounting tab

Pad pin hole

Rear caliper mounting bracket

Slot

Figure 2-132. Installing Rear Brake Pads

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2-88 2009 Sportster Service: Chassis

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Figure 2-147. Bleeding Hydraulic System (typical; XL model

shown)

sm05497

XR Models master cylinder

XL Models master cylinder

Figure 2-148. Front Brake Master Cylinder Identification

sm01814

Washer (dual front disc models: 6, all others: 4)

Banjo bolt (dual front disc models: 3, all others:
2)

Hydraulic brake line (single front disc models)

Clamp

Screw

Hydraulic brake line (dual front disc XL models)

Clamp (single front disc models)

Screw with captive washer

Clamp (dual front disc models)

10. Hydraulic brake line (dual front disc XR models)
11. Brake line manifold (dual front disc models)

Figure 2-149. Front Brake Line (typical)

Installation

NOTE

Master cylinder housings have various positive stops for banjo
fittings, based on the model being repaired. The front brake
systems as used on XR models and XL models employ different
master cylinder housings as shown in

Figure 2-148

. Never

intermix system components. When tightening the banjo bolt
in the next step, verify the banjo fitting is properly oriented and
contacts the positive stop.

See

Figure 2-149

. Note that hydraulic brake line is made

up of thin tube construction and flexible hose sections.
Position new washers (1) on each side of banjo fitting on
end of brake line with shortest flexible hose section. Insert

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2-98 2009 Sportster Service: Chassis

banjo bolt (2) through washers and banjo fitting. Loosely
install banjo bolt into master cylinder.

Route brake line downward in front of right handlebar, and
inward behind fork brackets. Install clamp (4) around lower
fitting of upper flexible hose section. Loosely attach clamp
to front fork upper bracket (XL models) or lower bracket
(XR models) with screw (5).

Continue routing brake line downward crossing to left side
of the vehicle under front fork lower bracket.

Clamp brake line to stem at bottom of front fork lower
bracket.

Dual front disc models: Install screw with captive
washer (8) through brake line manifold (11) and clamp
(9). Loosely thread screw into front fork lower bracket
stem.

Single front disc models: Install clamp (7) around top
fitting of long flexible hose section. Loosely attach
clamp to front fork lower bracket stem with screw with
captive washer (8).

NOTE

Single front disc models must have line positioned to maintain
a gap between line and lower fork bracket. Dual front disc
models will self-align creating a gap by default, but the gap
should be visually confirmed.

Single front disc models: See

Figure 2-150

. Measure dis-

tance between front brake line metal tubing and lower fork
bracket adjacent to pinch bolt. Move brake line assembly
forward or back until there is a 1/4 in. (6.35 mm) gap
between brake line and lower fork bracket.

Do not bend metal brake line. Bending brake line could
cause metal fatigue and brake failure, which could result
in death or serious injury. (00543b)

See

Figure 2-149

. While maintaining proper gap between

brake line and lower fork bracket, tighten screw (8) to 120-
168 in-lbs (13.6-19.0 Nm).

Position new washers (1) on each side of banjo fitting at
free end of brake line. Insert banjo bolt(s) (2, 3) through
washers and banjo fitting of each caliper. Loosely install
banjo bolt into each caliper.

NOTE

Master cylinder housing has a positive stop for banjo fitting.
When tightening banjo bolt into master cylinder in the next
step, rotate banjo fitting clockwise until it contacts positive stop.

Tighten banjo bolt (2) into master cylinder to 20-25 ft-lbs
(27.1-33.9 Nm).

Tighten screw (5) to 45-65 in-lbs (5.1-7.4 Nm).

NOTE

Brake caliper housing has a positive stop for banjo fitting. When
tightening banjo bolt into brake caliper in the next step, rotate
banjo fitting clockwise until it contacts positive stop.

10. Tighten banjo bolt into brake caliper to 20-25 ft-lbs (27.1-

33.9 Nm). Dual front disc models: repeat this step for other
front brake caliper.

11. Fill master cylinder with new HARLEY-DAVIDSON D.O.T.

4 BRAKE FLUID and bleed brakes. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

. Test operation of brake

lever.

12. Tighten bleeder valve to 35-61 in-lbs (4.0-6.9 Nm). Install

bleeder nipple cap. Dual front disc models: repeat this
step for other front brake caliper.

13. Test ride motorcycle. If front brake feels spongy, bleed

system again. See

1.8 BLEEDING HYDRAULIC BRAKE

SYSTEM

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Front brake line

Lower fork bracket pinch bolt

Ruler

Figure 2-150. Measuring Front Brake Line Clearance

REAR BRAKE LINE: XL MODELS

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2009 Sportster Service: Chassis 2-99

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Removal

Drain rear brake master cylinder reservoir. See

2.15 REAR

BRAKE MASTER CYLINDER RESERVOIR

Remove bleeder nipple cap from bleeder valve on rear
brake caliper. Install end of a length of 5/16 in. (7.9 mm)
I.D. clear plastic tubing over caliper bleeder valve, while
placing free end in a suitable container. Open bleeder
valve about 1/2 turn. Pump brake pedal to drain brake
fluid. Close bleeder valve.

See

Figure 2-151

. Unplug harness connectors [121] from

stop lamp switch (7).

Remove banjo bolt (2) and washers (1) to detach rear
brake line (3) from master cylinder body and rear brake
caliper. Discard washers.

Remove screw (5) to detach brake line clamp (4) with
bushing (12) from rear fork.

Remove screw (10) to detach brake line clamp (9) from
battery tray bracket.

Remove screw (11) securing brake line/switch tee (6) to
battery tray bracket.

Feed brake line up through B-clamp (8).

Hold hex body of brake line/switch tee with an open-end
wrench. Using a 1.0-in. six-point deep socket, remove stop
lamp switch from brake line/switch tee.

sm01815

Washer (4)

Banjo bolt (2)

Rear brake line

Clamp

Screw

Brake line/switch tee

Stop lamp switch assembly

B-clamp

Clamp

10. Screw
11. Screw
12. Bushing

Figure 2-151. Rear Brake Line: XL Models

Installation

See

Figure 2-151

. Thread stop lamp switch (7) into brake

line/switch tee (6) on new rear brake line (3). Hold hex
body of brake line/switch tee with an open-end wrench.
Using a 1.0-in. six-point deep socket, tighten stop lamp
switch assembly to 80-123 in-lbs (9.0-13.9 Nm).

Feed rear brake line down through B-clamp (8).

Position brake line/switch tee mounting bracket on battery
tray bracket. Secure with screw (11). Tighten to 72-120
in-lbs (8.14-13.6 Nm).

Install clamp (9) and screw (10) to secure rear brake hose
to battery tray bracket. Tighten screw to 30-40 in-lbs (3.4-
4.5 Nm).

NOTE

When installing clamp (4), bushing (12) and screw (5) in the
next step, make sure to adjust brake hose length between rear
caliper and clamp so there is no extra length. Do not twist or
stretch brake hose. Make sure bushing sits squarely in clamp
and around hose.

Install clamp (4) with bushing (12) and screw (5), to secure
rear brake hose to rear fork. Tighten screw to 30-40 in-
lbs (3.4-4.5 Nm).

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2-100 2009 Sportster Service: Chassis

NOTE

Master cylinder and brake caliper housings have a positive
stop for banjo fitting. When tightening banjo bolt into master
cylinder and brake caliper in the next step, rotate banjo fitting
clockwise until it contacts positive stop.

Position new washers (1) on each side of banjo fittings
by rear brake master cylinder and rear brake caliper. Insert
banjo bolts (2) through washers and banjo fittings. Tighten
to 20-25 ft-lbs (27.1-33.9 Nm).

NOTE

Rear brake master cylinder reservoir must be in a level position
when filling and checking fluid level.

Position motorcycle upright (not resting on jiffy stand). Fill
rear brake master cylinder reservoir with HARLEY-DAV-
IDSON D.O.T. 4 BRAKE FLUID and bleed brake system.
See

1.8 BLEEDING HYDRAULIC BRAKE SYSTEM

Tighten bleeder valve to 35-61 in-lbs (4.0-6.9 Nm). Install
bleeder nipple cap.

Turn the ignition/light switch ON. Test operation of brake
lamp with the rear brake applied.

10. Test ride motorcycle. If rear brake feels spongy, bleed

system again. See

1.8 BLEEDING HYDRAULIC BRAKE

SYSTEM

REAR BRAKE LINE: XR MODELS

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Removal

Drain rear brake master cylinder reservoir. See

2.15 REAR

BRAKE MASTER CYLINDER RESERVOIR

See

Figure 2-152

. Unplug harness connectors [121] from

stop lamp switch (2).

Remove banjo bolts (4) and washers (5) to detach rear
brake line (3) from master cylinder body and rear brake
caliper. Discard washers.

Remove fasteners (7) to detach brake line clamps (6) from
rear fork.

Remove fasteners (8) securing brake line bracket/switch
tee (1) to lower frame.

Hold hex body of brake line bracket/switch tee with an
open-end wrench. Using a 1.0-in. six-point deep socket,
remove stop lamp switch from brake line bracket/switch
tee assembly.

If necessary, remove clamp and bushing (9).

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2009 Sportster Service: Chassis 2-101

sm05316

Brake line bracket/switch tee

Stop lamp switch assembly

Rear brake line

Banjo bolt (2)

Washer (4)

Clamp (2)

Fastener (2)

Clamp and bushing

Figure 2-152. Rear Brake Line: XR Models

Installation

See

Figure 2-152

. Thread stop lamp switch (2) into brake

line bracket/switch tee (1) on rear brake line (3). Hold hex
body of brake line bracket/switch tee with an open-end
wrench. Using a 1.0-in. six-point deep socket, tighten stop
lamp switch assembly to 80-123 in-lbs (9.0-13.9 Nm).

If removed, install clamp and bushing (9).

Route brake line assembly to master cylinder and brake
caliper. Loosely install new washers (5) and banjo bolts
(4) to hold line in place.

Position brake line bracket/switch tee on lower frame and
secure with fasteners (8). Tighten to 17-22 in-lbs (1.9-2.5
Nm).

Connect harness connectors [121] to brake lamp switch
(2).

NOTE

With new washers (5) on each side of banjo fittings, tighten
banjo bolts (4) to 20-25 ft-lbs (27.1-33.9 Nm).

Secure brake line to bottom of rear fork with clamps (6)
and fasteners (7).

NOTE

Rear brake master cylinder reservoir must be in a level position
when filling and checking fluid level.

Position motorcycle upright (not resting on jiffy stand). Fill
rear brake master cylinder reservoir with HARLEY-DAV-
IDSON D.O.T. 4 BRAKE FLUID and bleed brake system.
See

1.8 BLEEDING HYDRAULIC BRAKE SYSTEM

Tighten bleeder valve to 35-61 in-lbs (4.0-6.9 Nm). Install
bleeder nipple cap.

10. Turn the ignition/light switch ON. Test operation of brake

lamp with the rear brake applied.

11. Test ride motorcycle. If rear brake feels spongy, bleed

system again. See

1.8 BLEEDING HYDRAULIC BRAKE

SYSTEM

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2-102 2009 Sportster Service: Chassis

2.19

TIRES

GENERAL

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)

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)

New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the stack
compresses the tires and closes down the beads.

Tires should be inspected for punctures, cuts, breaks and wear
at least weekly.

See

Figure 2-153

. The tread wear indicator bars will appear

on tire tread surfaces when 1/32 in. (0.8 mm) or less of tread
remains. Always remove tires from service before they reach
the tread wear indicator bars.

New tires are needed if any of the following conditions exist.
See

1.11 TIRES AND WHEELS

Tire wear indicator bars are visible on the tread surfaces.

Tire cords or fabric are visible through cracked sidewalls,
snags or deep cuts.

A bump, bulge or split in the tire.

Puncture, cut or other damage to the tire that cannot be
repaired.

sm02177

Sidewall

Tread surface

Figure 2-153. Tread Wear Indicators (Typical)

REMOVAL

NOTE

Care must be taken when removing and installing tire to prevent
cosmetic damage to wheel. This is especially true with wheels
that feature painted surfaces.

Remove wheel from motorcycle:

Front wheel: see

2.4 WHEELS, Front Wheel

Rear wheel: see

2.4 WHEELS, Rear Wheel

Deflate tire.

NOTE

On tube type wheels, it is not necessary to completely remove
tire from rim. Removing one side allows the tube to be replaced
and allows for inspection of tire.

Loosen both tire beads from rim flange. In most cases, a
bead breaker machine will be required to loosen the beads
from the rim.

Remove tire.

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2009 Sportster Service: Chassis 2-103

CLEANING, INSPECTION AND REPAIR

Clean the inside of tire and outer surface of tube.

If rim is dirty or rusty, clean with a stiff wire brush.

Check wheels for lateral and radial runout before installing
a new tire.

Models with laced wheels: see

2.8 TRUING LACED

WHEELS

Models with cast wheels: see

2.9 CHECKING CAST

WHEEL RUNOUT

Inspect the tire and tube for wear and damage. Inspect
tread depth. Replace worn tires. Replace damaged tubes.

Replace punctured or damaged tires. In some cases, small
punctures in the tread area may be repaired from within
the demounted tire by a Harley-Davidson dealer. Speed
should NOT exceed 50 mph (80 km/h) for the first 24 hours
after repair, and the repaired tire should NEVER be used
over 80 mph (130 km/h). Failure to follow this warning
could result in death or serious injury. (00015a)

Tubeless tires may be repaired in the tread area only if
the puncture is 1/4 in. (6.4 mm) or smaller. All repairs must
be made from inside the tire.

Acceptable repair method involves the use of a patch and
plug combination.

INSTALLATION

Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)

Do not exceed manufacturer's recommended pressure to
seat beads. Exceeding recommended bead seat pressure
can cause tire rim assembly to burst, which could result
in death or serious injury. (00282a)

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)

For tire pressures, see

1.11 TIRES AND WHEELS, Tires

Some tires have arrows molded into the tire sidewall. These
tires should be mounted on the rim with the arrow pointing in
the direction of forward rotation. The colored dot on the sidewall
is a balance mark and should be located next to the valve stem
hole.

Tube Type Tires

Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a Harley-Davidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on
the rim or cause tire failure, which could result in death
or serious injury. (00023a)

Use inner tubes on laced (wire spoked) wheels. Using
tubeless tires on laced wheels can cause air leaks, which
could result in death or serious injury. (00025a)

NOTES

•

For correct tire and tube types, see

2.2 SPECIFICATIONS

•

Whenever a tube type tire is replaced, the tube should
also be replaced. Inner tubes should be patched only as
an emergency measure. Replace a damaged or patched
tube as soon as possible. Rim bands must be used on all
laced wheels.

See

Figure 2-154

. On laced wheels, install a rim strip into

the rim well. Make sure no spokes protrude through
nipples, and be sure to align the valve stem hole in rim
strip with valve stem hole in rim.

Install tube and tire.

sm02466

Figure 2-154. Installing Rim Strip

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2-104 2009 Sportster Service: Chassis

Tubeless Tires

Only install original equipment tire valves and valve caps.
A valve, or valve and cap combination, that is too long or
too heavy can strike adjacent components and damage
the valve, causing rapid tire deflation. Rapid tire deflation
can cause loss of vehicle control, which could result in
death or serious injury. (00281a)

See

Figure 2-155

. On tubeless wheels, damaged or

leaking valve stems must be replaced. Install rubber
grommet (3) on valve stem.

Insert valve stem into rim hole.

Install metal washer (2).

Install nut and tighten to 12-15 in-lbs (1.4-1.7 Nm).

Install tire.

sm02467

Nut

Metal washer

Rubber grommet

Figure 2-155. Tubeless Tire Valve Stem

CHECKING TIRE RUNOUT

Lateral Runout

See

Figure 2-156

. Turn wheel on axle and measure

amount of displacement from a fixed point to tire sidewall.

Tire tread lateral runout should be no more than 0.090 in.
(2.29 mm). If runout exceeds this specification, remove
tire from rim, and check rim bead side runout to see if rim
is at fault.

If rim bead seat runout is less than 0.030 in. (0.76 mm),
then tire is at fault and must be replaced. If rim bead seat
runout is greater than 0.030 in. (0.76 mm), correct by
tightening selected spoke nipples (laced wheels) or replace
wheel (cast wheels). Install tire and check tire tread radial
runout again.

sm01803

Figure 2-156. Checking Tire Lateral Runout

Radial Runout

See

Figure 2-157

. Turn wheel on axle and measure tread

radial runout.

Tire tread radial runout should not be greater than 0.090
in. (2.29 mm). If runout exceeds this specification, remove
tire from rim and check rim bead runout to determine if
rim is at fault.

sm01804

Figure 2-157. Checking Tire Radial Runout

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2009 Sportster Service: Chassis 2-105

WHEEL BALANCING

TOOL NAME

PART NUMBER

WHEEL TRUING STAND

HD-99500-80

Wheel balancing is recommended to improve handling, and to
reduce vibration, especially at high road speeds.

In most cases, static balancing using WHEEL TRUING
STAND (Part No. HD-99500-80) will produce satisfactory res-
ults. However, dynamic balancing, utilizing a wheel spinner,
can be used to produce finer tolerances for best high-speed
handling characteristics. Follow the instructions supplied with
the balance machine you are using.

The maximum weight permissible to accomplish balance is 3-
1/2 oz. (99.2 g) (total weight applied to the rim). Wheels should
be balanced to within 1/2 oz. (14 g) at 60 mph (97 km/h).

Weights for Laced Wheels

Harley-Davidson specifies the following spoke balance weights,
which are crimped over the spoke nipple.

Table 2-23. Laced Wheel Balance Weights

PART NUMBER

WEIGHT (MASS)

GRAMS

OZ. (U.S.)

95578-41

1/2

95581-47

3/4

95582-47

Weights for Cast Wheels

Harley-Davidson specifies the following cast wheel balance
weights, which have special self-adhesive backings.

Table 2-24. Cast Wheel Balance Weights

HD PART

NUMBER

FINISH

WEIGHT (MASS)

GRAMS

OZ. (U.S.)

95594-84

black

1/4

95595-84

silver

1/4

These weights are applied to the flat surface of the wheel rim
according to the following procedures.

Make sure that area of application is completely clean,
dry, and free of oil and grease.

NOTE

If 1 oz. (28 g) or more of weight must be added at one location,
split the amount so that half is applied to each side of rim.

Remove paper backing from weight. Apply three drops of
LOCTITE® SUPERBONDER® 420 to the adhesive side
of the weight. Place the weight on flat surface of wheel
rim. Press weight firmly in place, and hold for ten seconds.

Allow eight hours for adhesive to cure completely before
using wheel.

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2-106 2009 Sportster Service: Chassis

2.20

LEFT SIDE COVER

GENERAL

See

Figure 2-158

. The left side cover provides access to the

battery (1), fuses (3, 4) and diagnostic electrical connector (5).
No tools are required to open or close the cover.

See

Figure 2-159

Figure 2-160

. The left side cover is

secured to the motorcycle by two upper slots that fit into clips
(XL models) or two molded-in posts that fit into grommets (XR
models). The side cover is also secured to the vehicle by a
bottom slot that fits onto a mounting tab on the battery tray.

NOTE

The left side cover does not need to be completely removed
from the vehicle to access the battery or fuses.

sm01342

Battery

Positive (+) battery terminal (under protective
rubber boot)

Main fuse and holder

System fuses and relays

Diagnostic connector (data link)

Figure 2-158. Main Fuse and Battery Location: All Models

(XL Model Shown)

OPENING LEFT SIDE COVER

Place a clean, dry cloth over rear brake master cylinder
reservoir and left passenger foot peg (if equipped). This
will protect left side cover from damage.

See

Figure 2-159

Figure 2-160

. Grasp left side cover

at upper corners and gently pull away from plastic
mounting clips (XL models) or grommets (XR models) on
frame.

sm01416

Mounting clips (on frame)

Mounting tab (on battery tray)

Side cover mounting slots (top)

Side cover mounting slot (bottom)

Figure 2-159. Left Side Cover: XL Models

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2009 Sportster Service: Chassis 2-107

sm05351

Mounting grommets (on frame)

Mounting tab (on battery tray)

Side cover mounting posts (top)

Side cover mounting slot (bottom)

Figure 2-160. Left Side Cover: XR Models

sm01417

Battery tray assembly

Mounting tab

Side cover (closed)

Side cover (open)

Figure 2-161. Left Side Cover Bottom Mount: All Models

See

Figure 2-161

. While rotating top of cover out away

from motorcycle, slide cover down slightly so mounting
slot on cover slides down mounting tab (2) on battery tray
assembly (1). See

Figure 2-162

. Side cover (3) will now

rest on top of rear brake master cylinder reservoir and left
passenger footrest (if equipped) with slot (2) hanging off
bottom of mounting tab (1).

Leaning or placing tools on side cover could cause
damage to cover and/or mounting tab on battery tray.
(00523b)

sm01418

Side cover mounting tab (on battery tray)

Mounting slot (bottom of left side cover)

Left side cover

Figure 2-162. Left Side Cover in Open Position: All Models

(XL Model Shown)

CLOSING LEFT SIDE COVER

See

Figure 2-162

. Grasp top corners of side cover (3).

While rotating top of cover up toward motorcycle, gently
pull cover up so that mounting slot (2) slides up mounting
tab (1).

Press top of side cover into place:

XL models: see

Figure 2-159

. Line up top slots of

side cover with mounting clips (1) on motorcycle
frame, aligning with front clip first. Press top of side
cover into clips until snug.

XR models: see

Figure 2-160

. Line up molded-in

posts in top of side cover with mounting grommets
on motorcycle frame. Press posts in side cover into
grommets until snug.

NOTE

Side cover should snap into place with minimal pressure. Using
excessive force or striking side cover to close it can damage
mounting clips (XL models) or molded-in posts (XR models).

REMOVING LEFT SIDE COVER

NOTE

It is rarely necessary to remove the left side cover completely.
However, if left side cover removal is necessary, use the fol-
lowing procedure.

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2-108 2009 Sportster Service: Chassis

See

Figure 2-159

Figure 2-160

. Grasp side cover at

upper corners and gently pull away from plastic mounting
clips (XL models) or grommets (XR models) on frame.

See

Figure 2-163

. Lift side cover up and tilt cover to the

rear of the motorcycle. With a slight back and forth rocking
motion, pull up gently until cover disengages from
mounting tab on battery tray.

sm01419

Figure 2-163. Removing Left Side Cover: All Models (XL

Model Shown)

INSTALLING LEFT SIDE COVER

NOTE

It is rarely necessary to remove the left side cover completely.
However, if left side cover has been removed, reinstall cover
as described in the following procedure.

See

Figure 2-162

. Position side cover over battery tray

assembly with slot in bottom of cover resting on mounting
tab on battery tray.

Gently press downward on side cover until slot snaps
down over mounting tab.

Now close left side cover. See

2.20 LEFT SIDE COVER,

Closing Left Side Cover

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2009 Sportster Service: Chassis 2-109

2.21

FRONT FORK: XL MODELS

GENERAL

The front fork consists of two telescoping tube/slider assem-
blies. Each tube/slider assembly has an internal compression
spring, which supports the forward weight of the vehicle/rider
and extends and retracts to cushion the ride over rough or
irregular road surfaces. An oil-filled damping mechanism con-
trols the telescoping action of each tube/slider assembly.

REMOVAL

Remove front brake caliper(s). See

2.11 FRONT BRAKE

CALIPER: XL MODELS

Remove front wheel assembly. See

2.4 WHEELS

Remove front fender mounting screws and lock nuts.
Remove fender. See

2.33 FRONT FENDER

See

Figure 2-164

. Loosen, but do not remove, slider tube

caps (12).

Loosen front fork upper and lower bracket pinch screws
(11 and 14). Remove fork assemblies (13) from fork
brackets.

DISASSEMBLY

See

Figure 2-165

. Remove drain screw and washer (19)

from slider (16). Remove tube cap (7) from slider tube (9).
Drain fork oil. Remove o-ring (6) from tube cap.

Remove spring (5) from slider tube.

All except XL 1200L: Remove spring collar (20) and
spring washer (21) from slider tube.

All except XL 1200N: Remove cover (11).

NOTE

See

Figure 2-166

. The XL 1200N is equipped with fork gaiters

(2) instead of metal covers. The lower lip (3) of the fork gaiter
fits into the groove at the upper end of the fork slider (1). The
upper end of the fork gaiter fits tightly around the slider tube,
just below the front fork lower bracket (4).

XL 1200N: See

Figure 2-166

. Peel back lower lip (3) of

fork gaiter (2) from slider groove and slide fork gaiter up
and off end of slider tube.

See

Figure 2-165

. Remove dust seal (12). Compress

internal circle clip (13). Remove clip from groove in top of
slider bore.

Remove screw (18) and washer (17) from bottom of slider.

NOTE

Since there is little resistance to damper tube (3) rotation within
slider tube (9) when removing screw (18), use an air impact
wrench for best results.

Withdraw slider tube (9) from slider until lower bushing
(10) on slider tube contacts upper bushing (1) in slider.
Use lower bushing on slider tube in a slide hammer motion
to gently tap out oil seal (14), spacer (2) and upper bushing
from slider bore.

Remove sleeve (15). Sleeve will be found within slider or
on bottom end of damper tube (3).

10. Insert a small diameter rod through opening in bottom of

slider tube to remove damper tube assembly.

11. Remove rebound spring (8) from damper tube.

12. Remove damper tube ring(s) (4) from damper tube.

13. Remove lower bushing from damper tube only if replace-

ment is necessary.

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2-110 2009 Sportster Service: Chassis

Harley Davidson Sportster Models 2009. Service Repair Manual - page 23