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Harley Davidson Sportster Models 2009. Service Repair Manual - page 24

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Front fork lower bracket and stem

Seal, lower

Bearing cone (2)

Bear cup (2)

Seal, upper

Front fork upper bracket

Fork stem pinch screw

Washer

Fork stem bolt

10. Fork stem bolt cap (XL 1200R/L only)
11. Pinch screw, upper (2)
12. Slider tube cap
13. Fork assembly (slider and tube assembly, RH and LH)
14. Pinch screw, lower (2)
15. Steering head (part of frame)
16. XL models: 0.42-0.50 in. (10.7-12.7 mm); XR models: 0.25-0.33 in. (6.35-8.38 mm)

Figure 2-164. Front Fork Assembly: XL Models

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2009 Sportster Service: Chassis 2-111

CLEANING, INSPECTION AND REPAIR

Thoroughly clean and inspect all parts. Replace any parts
that are bent or damaged.

See

Figure 2-165

. Inspect the o-ring (6) for damage, wear

or general deterioration; replace as necessary. Replace
all other removed seals.

Inspect damper tube ring(s) (4). Replace ring(s) if dam-
aged or excessively worn.

Check dust seal (12) where it contacts slider tube (9). Dust
seal should provide continuous contact against slider tube
and should not show excessive wear. Check slider tube
where it is contacted by seal. Tube surface should be
shiny, smooth and free of scoring or abrasions.

Inspect small hole in groove of slider tube lower end. Verify
that hole is unobstructed.

ASSEMBLY

TOOL NAME

PART NUMBER

FORK SEAL AND BUSHING
INSTALLATION TOOL

HD-36583

See

Figure 2-165

. If lower bushing (10) was removed,

install new lower bushing in groove of slider tube (9).
Expand bushing only enough to fit over tube.

Install damper tube ring(s) (4) into groove(s) of damper
tube (3).

Place rebound spring (8) over damper tube (3). Insert
damper tube into slider tube.

Insert spring (5) into slider tube with the tapered end down.
Push damper tube through opening at bottom of slider

tube using spring. Place sleeve (15) over end of damper
tube.

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

Install slider tube assembly into slider (16). Install screw
(18) with washer (17) at bottom of slider. Move slider tube
through its full range of travel within slider several times
to verify proper component alignment. Then, applying
downward force on spring, final tighten screw to 132-216
in-lbs (14.9-24.4 Nm).

Place upper bushing (1), spacer (2) (concave side down-
ward), oil seal (14) (lettering side upward) and FORK SEAL
AND BUSHING INSTALLATION TOOL (Part No. HD-
36583) over slider tube. Install bushing, spacer and seal
into slider bore by tapping components downward with
the installation tool. Install internal circle clip (13) into
groove in top of slider bore.

Install dust seal (12) at top of slider.

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

10. XL 1200N: See

Figure 2-166

. Slide a fork gaiter (2) down

each slider tube. Peal back lower lip (3) and slip over end
of fork slider (1), fitting lower lip down over groove in upper
end of fork slider. Slide upper end of fork gaiter down as
far as possible.

11. See

Figure 2-165

. Install drain screw and washer (19) into

lower end of slider.

12. Pour the proper amount of TYPE "E" HYDRAULIC FORK

OIL into top end of slider tube. See

1.22 FRONT FORK

OIL

13. Install slider tube cap (7) with o-ring (6). Screw tube cap

all the way into slider tube. Finger-tighten only at this time.

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12.

Dust seal

Upper bushing

13.

Spacer

Internal circle clip

14.

Oil seal

Damper tube

15.

Damper tube ring

Sleeve

16.

Slider

Spring

17.

O-ring

Washer

18.

Screw

Tube cap

19.

Rebound spring

Drain screw and washer

20.

Spring collar (all except XL 1200L)

Slider tube

10.

21.

Lower bushing

Spring washer (all except XL 1200L)

22.

11.

Fork gaiter (XL 1200N) only)

Cover (all except XL 1200N)

Figure 2-165. Front Slider Tube/Slider Assembly: XL Models

INSTALLATION

See

Figure 2-164

. Insert each fork assembly (13) through

front fork lower (1) and upper (6) brackets. Position slider
tubes so that top of each tube cap (12) extends 0.42-0.50

in. (10.7-12.7 mm) above top surface of front fork upper
bracket.

Tighten front fork upper and lower bracket pinch screws
(11 and 14) to 30-35 ft-lbs (40.7-47.5 Nm).

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2009 Sportster Service: Chassis 2-113

Now tighten slider tube caps to 22-58 ft-lbs (29.9-78.7
Nm).

XL 1200N: See

Figure 2-166

. Slide upper end of each

fork gaiter (2) up until it contacts underside of front fork
lower bracket (4).

Install front fender. See

2.33 FRONT FENDER

. Tighten

fasteners to 96-156 in-lbs (10.9-17.6 Nm).

Install front wheel assembly and front brake caliper. See

2.4 WHEELS

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Fork slider (2)

Fork gaiter (2)

Fork gaiter lower lip

Front fork lower bracket

Figure 2-166. Fork Gaiter: XL 1200N Only

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2-114 2009 Sportster Service: Chassis

2.22

FRONT FORK: XR 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

TOOL NAME

PART NUMBER

TRIPLE TREE WEDGE TOOL

HD-48287

Remove front brake calipers. See

2.12 FRONT BRAKE

CALIPER: XR MODELS

Remove front wheel assembly. See

2.4 WHEELS

Remove front fender and bracket assembly. See

2.33 FRONT FENDER

See

Figure 2-167

. Remove upper and lower fork bracket

pinch bolts.

Using TRIPLE TREE WEDGE TOOL (Part No. HD-48287),
insert wedge in fork brackets to relieve clamping pressure
on fork tubes.

Remove fork from upper and lower fork brackets.

Repeat steps for other side.

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Figure 2-167. Insert Triple Tree Wedge (typical)

DISASSEMBLY

TOOL NAME

PART NUMBER

FORK TUBE HOLDER

HD-41177

FRONT FORK COMPRESSOR

HD-45966

INNER FORK NUT
REMOVER/INSTALLER

HD-47852

Left Side

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

NOTES

•

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

•

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

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Figure 2-168. Clamp Fork and Remove Fork Cap

See

Figure 2-168

. Using FORK TUBE HOLDER (Part

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

Remove fork cap.

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2009 Sportster Service: Chassis 2-115

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Figure 2-169. Compress Fork Assembly

See

Figure 2-169

. Compress fork using FRONT FORK

COMPRESSOR (Part No. HD-45966).

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Fork cap

Retaining nut

Keeper

Figure 2-170. Remove Keeper

NOTE

Note position of retaining nut with shoulder of nut facing away
from fork cap. Be sure to install in the same manner.

See

Figure 2-170

. Remove keeper and loosen retaining

nut, and fork cap from cartridge assembly.

Remove Front Fork Compressor.

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Figure 2-171. Remove Collar, and Spring Assembly

See

Figure 2-171

. Remove collar and spring from fork

assembly.

Remove fork from vise and drain fork oil into a suitable
container by tipping fork upside down and stroke cartridge
plunger to remove excess fork oil.

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2-116 2009 Sportster Service: Chassis

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Figure 2-172. Remove Fastener and Copper Washer

NOTE

Always use soft jaws for bench vise when placing any fork
components into vise to prevent damage to components.

See

Figure 2-172

. Place fork slider into bench vise with

soft-jaws and remove fastener and copper washer from
bottom of fork assembly.

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Figure 2-173. Cartridge Assembly

Remove fork from vise.

10. See

Figure 2-173

. Place fork in vise using FORK TUBE

HOLDER (Part No. HD-41177). Remove cartridge
assembly from fork slider.

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Figure 2-174. Remove Chrome Dust Cover

11. See

Figure 2-174

. Using a blunt soft object (such as a

wood dowel or chisel with duct tape), gently tap chrome
dust cover away from seat, remove dust seal, lock ring,
fork seal, spacer, and bushing from fork tube. Then,
expand fork tube and slider against each other (in a slider-
hammer effect) repeatedly to free fork slider from fork tube.
Use caution not to damage components.

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Bushing

Spacer

Fork seal

Lock ring

Dust seal

Figure 2-175. Seal Components

12. See

Figure 2-175

. Once fork tube and slider are separated,

remove dust seal, lock ring, fork seal, spacer, bushing and
chrome dust cover (not shown) from fork slider.

Right Side

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2009 Sportster Service: Chassis 2-117

See

Figure 2-176

. Using FORK TUBE HOLDER (Part

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

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Figure 2-176. Clamp Fork and Loosen Fork Cap

Loosen fork cap.

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Fork cap

Retaining nut

Figure 2-177. Remove/Install Fork Cap and Retaining Nut

See

Figure 2-177

. Back retaining nut away from fork cap.

Remove fork cap and retainer nut from inner fork nut
threaded shaft.

NOTE

Do not fully extend fork assembly. Extending fork will cause
oil to leak from bleed hole.

See

Figure 2-178

. Using INNER FORK NUT

REMOVER/INSTALLER (Part No. HD-47852) and remove
inner fork nut assembly from fork tube.

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Figure 2-178. Inner Fork Nut

NOTE

Note positioning of collar, washer and spring for assembly.

See

Figure 2-179

. Remove collar, washer and spring from

fork assembly.

Remove fork from vise and drain fork oil into a suitable
container by tipping fork upside down and drain excess
fork oil into suitable container.

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Figure 2-179. Remove Collar, Washer and Spring

See

Figure 2-180

. Using FORK TUBE HOLDER (Part

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

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2-118 2009 Sportster Service: Chassis

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Figure 2-180. Remove Chrome Dust Cover

Using a blunt soft object (such as a wood dowel, or chisel
with duct tape), gently tap chrome dust cover away from
seat, remove dust seal, lock ring, fork seal, spacer, and
bushing from fork tube. Then, by expanding fork and slider
against each other (in a slider-hammer effect) repeatedly,
pull slider free from fork tube. Use caution not to damage
components.

sm03142

Bushing

Spacer

Fork seal (chamfered lips must face oil)

Lock ring

Dust seal

Figure 2-181. Seal Components

See

Figure 2-181

. Once fork tube and slider are separated,

remove dust seal, lock ring, fork seal, spacer, bushing and
chrome dust cover (not shown) from fork slider.

CLEANING AND INSPECTION

Thoroughly clean and inspect each part. If inspection
shows that any parts are bent or damaged, those parts
should be repaired or replaced.

Inspect fork tube bushing and slider guide bushing and
replace as required.

Always replace oil seals and o-rings.

Check dust cover there it rubs on fork tube. Dust cover
should not show any wear.

If springs are damaged, replace springs.

If a fork tube or slider is bent or damaged, replace it.

Replace all other worn or damaged components as
necessary.

NOTES

•

Any time fork pinch bolts are loosened or removed for any
reason, the following procedure must be performed. Fork
tube installation process is extremely critical and must
follow this procedure with no exceptions. Failure to prop-
erly clean the threads will cause improper torque readings
upon assembly, causing loss of vehicle control, resulting
in death or serious injury.

•

New bolts are recommended for assembly. If the original
bolts are to be reused, completely clean excess lock patch
from pinch bolt threads using a wire wheel. Wash bolts
with solvent and dry thoroughly before installing.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

•

Clean bolt holes using a bottoming thread tap and blow
bolt hole threads clean with compressed air.

Thoroughly clean all locking material from the fastener
and bracket bolt hole threads. Fork pinch bolts must be
thoroughly cleaned of all lock patch material. Fork bracket
bolt holes must be tapped with a bottoming tap and blown
clear with compressed air to remove excess lock patch
material. If bolts can not be completely cleaned, it is
required that new fork pinch bolts be installed.

ASSEMBLY

TOOL NAME

PART NUMBER

FORK SEAL DRIVER

B-42571

FRONT FORK TUBE HOLDER

HD-41177

FRONT FORK COMPRESSOR

HD-45966

INNER FORK NUT
REMOVER/INSTALLER

HD-47852

OIL LEVEL GAUGE

HD-59000B

Left Side

NOTE

Chamfered lips on oil seal MUST face towards oil in fork.

See

Figure 2-182

. Use sleeve from fork seal driver and

install chrome dust cover (not shown) and components
onto fork slider in order shown.

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2009 Sportster Service: Chassis 2-119

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Bushing

Spacer

Fork seal (chamfered lips must face oil)

Lock ring

Dust seal

Figure 2-182. Fork Tube Shown Installed In Order of

Installation

Lightly coat fork slider and bushing with fork oil and gently
install slider into fork tube.

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Fork cartridge

Fork tube

Figure 2-183. Install Fork Cartridge

See

Figure 2-183

. Using FRONT FORK TUBE

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

Make sure cap (centering plate) is on bottom end of fork
cartridge and install fork cartridge (big end first) into fork
slider.

Remove fork and FRONT FORK TUBE HOLDER from
vise.

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Figure 2-184. Install Fastener and Copper Washer

NOTE

Always use soft jaws for bench vise when placing any fork
components into vise to prevent damage to components.

See

Figure 2-184

. Using a vise with soft jaws, clamp fork

slider in vise. Install new fastener and copper washer to
hold fork cartridge in place inside fork tube. Tighten to
132-216 in-lbs (14.9-24.4 Nm).

Remove fork from vise.

Using FRONT FORK TUBE HOLDER (Part No. HD-
41177), mount fork assembly in vise.

See

Figure 2-185

. Assemble the FORK SEAL

DRIVER (Part No. B-42571) over fork slider in front of oil
seal with the long end of tool facing seal. Install parts in
the following order: bushing, spacer, and drive fork seal
into fork tube bore with tool until tool is flush with fork
slider.

10. Install lock ring into groove in top of oil seal. Verify lock

ring is properly seated.

sm03149

Figure 2-185. Install Bushing, Spacer, and Install Fork Seal

in Place with Seal Driver

11. See

Figure 2-186

. Remove FORK SEAL DRIVER, reverse

tool to short side of tool to prepare to install chrome dust
cover. Rotate slider cover to match any removal burrs in
slider and tap chrome dust cover into place.

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2-120 2009 Sportster Service: Chassis

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Figure 2-186. Install Chrome Dust Cover

Table 2-25. Oil Level, Left Fork

VOLUME

MEASUREMENT

613 cc

20.7 oz

71 mm

2.8 in.

12. Adjust fork assembly to be vertical in vise and fully com-

pressed.

13. Fill fork with Harley-Davidson TYPE E FORK OIL (Part

No. HD-99884-80) until it is approximately 2.0 in. (50.8
mm) from top of fork tube.

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Figure 2-187. Pump Cartridge

14. See

Figure 2-187

. Slowly pump cartridge 8 to 10 times to

exhaust air from assembly.

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Figure 2-188. Measure Fork Oil

NOTE

Fork oil level is measured from top of fork tube, with spacer
and spring removed and fork fully compressed.

15. See

Figure 2-188

. Fully compress fork and adjust the oil

level to specification from top of fork tube using OIL LEVEL
GAUGE (Part No. HD-59000B). Refer to

Table 2-25

NOTE

Coil windings tighten at bottom of spring. Be sure to install in
this manner.

16. See

Figure 2-189

. Fully extend fork and install spring in

fork tube (with tightly wound end at bottom), washer and
collar.

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Collar

Spring

Figure 2-189. Collar and Spring Assembly

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2009 Sportster Service: Chassis 2-121

17. See

Figure 2-190

. Compress fork using FRONT FORK

COMPRESSOR (Part No. HD-45966).

18. Install keeper.

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Figure 2-190. Install Keeper

19. Install retainer nut on cartridge rod 0.551 in. (14 mm) from

top of rod and install fork cap onto cartridge rod.

20. Install fork cap on inner rod and tighten against the retainer

nut to 150-195 in-lbs (17-22 Nm) while holding retainer
nut with wrench.

21. Release tension and remove fork compressing tool.

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Figure 2-191. Install Fork Cap

22. See

Figure 2-191

. Install fork cap and tighten to 21-29 ft-

lbs (29-39 Nm).

Right Side

Using FORK TUBE HOLDER (Part No. HD-41177), mount
fork assembly in vise vertically and fully compress fork.

See

Figure 2-192

. Install chrome dust cover (not shown)

and components onto fork slider in order shown.

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Bushing

Spacer

Fork seal (chamfered lips must face oil)

Lock ring

Dust seal

Figure 2-192. Seal Components

Lightly coat fork slider and bushing with fork oil and gently
install slider into fork tube.

sm03149

Figure 2-193. Install Seal Components

NOTE

Chamfered lips on oil seal MUST face towards oil in fork.

See

Figure 2-193

. Assemble the FORK SEAL

DRIVER (Part No. B-42571) over fork slider in front of oil
seal with the long end of tool facing seal and assemble in
the following order: Install bushing, spacer, and drive fork
seal into fork tube bore with tool until tool is flush with fork
slider.

Install lock ring into groove in top of oil seal. Verify lock
ring is properly seated.

See

Figure 2-194

. Remove FORK SEAL DRIVER and

reverse tool to short side of tool to prepare to install
chrome dust cover. Rotate slider cover to match any
removal burrs in slider and tap chrome dust cover into
place.

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2-122 2009 Sportster Service: Chassis

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Figure 2-194. Install Chrome Dust Cover

Table 2-26. Oil Level, Right Fork

VOLUME

MEASUREMENT

684 cc

23.1 oz

93 mm

3.7 in.

Using FORK TUBE HOLDER (Part No. HD-41177), mount
fork assembly in vise vertically and fully compress fork.

NOTE

Measure fork oil level from top of fork tube using the OIL LEVEL
GAUGE (Part No. HD-59000B).

Fill fork with Harley-Davidson TYPE E FORK OIL (Part
No. HD-99884-80) to specification shown in

Table 2-26

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Figure 2-195. Measure Fork Oil

Fully extend fork.

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Spring collar

Washer

Rebound spring

Figure 2-196. Collar, Washer and Spring Assembly

10. See

Figure 2-196

. Install rebound spring in fork tube (with

tightly wound end at bottom), washer, and spring collar.

11. Verify that washer has properly seated on top of spring.

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Figure 2-197. Inner Fork Nut

12. See

Figure 2-197

. Insert inner fork nut and finger tighten.

HOME

2009 Sportster Service: Chassis 2-123

NOTE

To prevent cross threading fork tube damper cups and caps,
use caution when threading in the caps with the spring com-
pressed. It may be helpful to use a palm-ratchet during this
process.

13. See

Figure 2-198

. Final tighten inner fork nut to 69-83 ft-

lbs (93-113 Nm) using INNER FORK NUT
REMOVER/INSTALLER (Part No. HD-47852).

sm03159

Figure 2-198. Hand Tighten

14. See

Figure 2-199

. Install retainer nut (retainer nut must

be installed 0.551 in (14 mm) from top of threaded shaft).

sm05680

Fork cap

Retaining nut

Figure 2-199. Remove/Install Fork Cap and Retaining Nut

15. Install fork cap on inner rod and tighten against the retainer

nut to 150-195 in-lbs (17-22 Nm) while holding retainer
nut with wrench.

16. Apply a light coat of fork oil on o-ring and thread cap into

fork tube. Tighten fork cap to 21-29 ft-lbs (29-39 Nm).

INSTALLATION

TOOL NAME

PART NUMBER

TRIPLE TREE WEDGE TOOL

HD-48287

Any time fork pinch bolts are loosened or removed for any
reason, the bolts and threaded holes must be completely clean
of excess lock patch material. If the threads have not been
properly cleaned, follow procedure in

2.22 FRONT FORK: XR

MODELS, Cleaning and Inspection

. Failure to properly clean

these threads will cause improper torque readings upon
assembly and can result in loss of vehicle control, death or
serious injury.

NOTES

•

It is recommended that new fork pinch bolts be installed.
If new bolts are not readily available, use a wire grinder
wheel to remove all remaining lock patch from original
bolts, wash bolts in clean solvent and dry thoroughly.

•

Fork tube installation height is also critical and must match
the opposite side exactly for proper vehicle operation,
reliability and performance.

•

When installing fork leg in triple trees, do not twist fork leg
to avoid damage to cosmetic finishes.

Identify left and right side fork assemblies.

Insert fork assembly from the lower fork bracket upward
through the upper fork bracket.

Remove TRIPLE TREE WEDGE TOOL (Part No. HD-
48287) used during removal process.

See

Figure 2-200

. Measure distance from top of upper

fork bracket to top of fork assembly. Both sides must be
exactly the same and measure 0.250-0.330 in (6.35-8.38
mm).

sm05356

Figure 2-200. Fork Installation Height Measurement

NOTE

If new bolts are not readily available, use a wire grinder wheel
to remove all remaining lock patch from original bolts, wash
bolts in clean solvent and dry thoroughly. Apply two drops of
LOCTITE® 262 to the first 1/4 in. (6.35 mm) of the end threads.
Install screws in triple clamp clamps.

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2-124 2009 Sportster Service: Chassis

Install new pinch bolts with lock patch or original bolts
using Loctite.

Verify fork tube installation measurement is 0.250-0.330
in (6.35-8.38 mm).

Tighten pinch bolts to 30-35 ft-lbs (40.7-47.5 Nm).

Install front fender and bracket. See

2.33 FRONT

FENDER

Install front brake caliper hydraulic lines and install front
brake calipers. See

2.12 FRONT BRAKE CALIPER: XR

MODELS

10. Install front wheel and align the wheel to the forks. See

2.4 WHEELS

11. Install negative battery cable. Tighten to 60-70 in-lbs (6.8-

7.9 Nm).

HOME

2009 Sportster Service: Chassis 2-125

2.23

FORK STEM AND BRACKET ASSEMBLY

REMOVAL AND DISASSEMBLY

Place a protective cover over fuel tank. Remove the fork
assemblies. See

2.21 FRONT FORK: XL MODELS

2.22 FRONT FORK: XR MODELS

See

Figure 2-201

. Remove stem bolt cap (10) (XL 1200R

only), fork stem bolt (9) and washer (8). Loosen fork stem
pinch screw (7).

Lift handlebar assembly from steering head with fork upper
bracket (6) attached. Carefully position assembly out of
the way. Exercise caution to avoid damaging control
cables, wiring harnesses, clutch cable or brake lines.

NOTE

It is not necessary to disconnect clutch and brake hand levers,
wiring harnesses or control cables from handlebar, unless the
handlebar assembly is to be removed from the motorcycle.

Remove upper seal (5) and upper bearing cone (3). Slide
fork stem and lower bracket (1) from frame.

sm01817

Front fork stem and lower bracket

Seal, lower

Bearing cone (2)

Bearing cup (2)

Seal, upper

Front upper bracket

Fork stem pinch screw

Washer

Fork stem bolt

10. Fork stem bolt cap (XL 1200R/L only)
11. Pinch screw, upper (2)
12. Pinch screw, lower (2)
13. Steering head (part of frame)

Figure 2-201. Fork Stem and Bracket Assembly: Typical

CLEANING, INSPECTION AND REPAIR

TOOL NAME

PART NUMBER

UNIVERSAL DRIVER HANDLE

HD-33416

STEERING HEAD BEARING RACE
REMOVAL TOOL

HD-39301-A

See

Figure 2-201

. Clean the seals (2, 5), bearing cones

(3), fork stem and lower bracket (1) and steering head (13)
with solvent.

HOME

2-126 2009 Sportster Service: Chassis

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