Harley Davidson Sportster Models 2009. Service Repair Manual - page 25

2.22 FRONT FORK: XR MODELS

Figure 2-201

. If bearing cups (4) were removed, obtain

new bearings and bearing cups. Install new bearing cups

into frame steering head using STEERING HEAD
BEARING RACE INSTALLATION TOOL (Part No. HD-
39302).

Properly seat bearing cups in steering head bore. Improper
seating can loosen fork stem bearings adversely affecting
stability and handling, which could result in death or ser-
ious injury. (00302a)

Liberally coat the bearing cones (3) with HARLEY-DAV-
IDSON SPECIAL PURPOSE GREASE. Work the grease
thoroughly into the bearing rollers.

Place lower bearing seal (2) over fork stem. Install lower
bearing cone (3) onto fork stem and bracket (1).

Insert fork stem and bracket (1) through the steering head.
Install bearing cone (3) and seal (5) onto the stem.

Install the upper bracket (6) including the handlebar
assembly and loosely install fork stem bolt (9) with washer
(8).

Install fork slider and tube assemblies. See

2.21 FRONT

FORK: XL MODELS

Leave both lower fork bracket pinch screws (12) loose.

Tighten fork stem bolt (9) to 23-27 ft-lbs (31.2-36.6 Nm).
Loosen fork stem bolt, then retighten to 72-96 in-lbs (8.1-
10.9 Nm).

Tighten lower fork bracket pinch screws to 30-35 ft-lbs
(40.7-47.5 Nm)

Tighten fork stem pinch screw (7) to 30-35 ft-lbs (40.7-
47.5 Nm).

2009 Sportster Service: Chassis 2-127

2.24

BELT GUARD AND DEBRIS DEFLECTOR

BELT GUARD: XL MODELS

Removal

. Remove right side lower shock absorber

mount lock nut (1). Pull shock absorber mounting screw
(2) out slightly until it clears mounting hole in belt guard
(4).

Remove screw (5), washer (6) and nut (7) securing front
of belt guard to rear fork (10).

Remove belt guard from vehicle.

Installation

See

. Slide belt guard (4) into place on

vehicle. Tab on front of belt guard mounts outboard of
mounting bracket on rear fork.

Secure front of belt guard to rear fork (10) with screw (5),
washer (6) and nut (7). Tighten to 120-180 in-lbs (13.6-
20.4 Nm).

Push lower shock absorber mounting screw (2) through
rear belt guard mounting hole. Thread lock nut (1) on
screw. Tighten to 45-50 ft-lbs (61-68 Nm).

DEBRIS DEFLECTOR: XL MODELS

Removal

See

. Loosen, but do not remove, three

screws with captive washers (9) securing debris deflector
(8) to underside of rear fork (10).

Slide debris deflector forward until keyway slots in deflector
clear screw heads. Remove debris deflector.

Installation

See

. Position debris deflector (8) in place on

underside of rear fork (10).

Fit large end of keyway slots in deflector over screw heads
and captive washers (9). Slide deflector rearward to lock
screws in slots. Tighten screws to 36-60 in-lbs (4.1-6.8
Nm).

sm02201

Lock nut

Screw

Washer

Belt guard

Screw

Washer

Nut

Debris deflector

Screw w/captive washer (3)

10. Rear fork

Figure 2-202. Belt Guard/Debris Deflector: XL Models

BELT GUARD: XR MODELS

Removal

NOTE

See

Figure 2-203

. Note that exhaust system has been removed

for clarity. It is not necessary to remove exhaust system to
remove and replace belt guard and/or debris deflector.

. Remove two screws with captive

washers (2) securing belt guard to top of rear fork (5).

Remove belt guard from vehicle.

Installation

See

. Slide belt guard (1) into place on top

of rear fork (5).

Secure belt guard using two screws with captive washers
(2). Tighten to 72-96 in-lbs (8.1-10.8 Nm).

2-128 2009 Sportster Service: Chassis

DEBRIS DEFLECTOR: XR MODELS

Removal

See

. Remove three screws with captive

washers (4) securing debris deflector (3) to underside of
rear fork (5). Note that front screw is located inboard of
debris deflector.

Remove debris deflector from vehicle.

Installation

See

. Position debris deflector (3) in place on

underside of rear fork (5).

Secure with three screws (4). Tighten screws to 72-96 in-
lbs (8.1-10.8 Nm).

sm04892

Belt guard

Screw with captive washer (2)

Debris deflector

Screw with captive washer (3) (front screw
inboard of debris deflector)

Rear fork

Figure 2-203. Belt Guard/Debris Deflector: XR Models

(Exhaust System Removed for Clarity)

4.15 EXHAUST SYSTEM: XL MODELS

2009 Sportster Service: Chassis 2-129

2.25

REAR FORK

GENERAL

The rear fork used on the XR model differs in appearance from
the XL model rear fork. However, the removal, servicing and
installation procedures are functionally identical.

REMOVAL

NOTE

Mark all hardware as it is removed so that it may be returned
to its original location.

Support motorcycle under frame with suitable lifting device
so that rear wheel is off the ground.

XL models: remove rear exhaust pipe and muffler. See

XR models: remove exhaust system. See

4.16 EXHAUST

SYSTEM: XR MODELS

Remove rear wheel. See

2.4 WHEELS

Remove rear brake caliper assembly from rear fork. See

2.16 REAR BRAKE CALIPER: XL MODELS

2.17 REAR

BRAKE CALIPER: XR MODELS

. Remove screw(s)

securing brake line clamp(s) to rear fork.

XR Models: Remove fasteners securing brake line to left
side of rear fork.

Remove both shock absorber screws, washers and nuts
from rear fork. See

2.26 SHOCK ABSORBERS

Remove rear belt guard and debris deflector. See

2.24 BELT GUARD AND DEBRIS DEFLECTOR

XL Models: Remove rear brake reservoir cover by
grasping cover and gently pulling straight out from reser-
voir. Remove reservoir mounting screw and pull reservoir
back out of the way. See

2.15 REAR BRAKE MASTER

CYLINDER RESERVOIR

10. XL Models: Loosen, but do not remove, top mounting

screw from left passenger footrest bracket. Remove bottom
mounting screw. Move brake hoses and B-clamp forward
slightly to gain access to left rear fork/engine mount bolt.

11. XR Models: Remove left and right rider footrests. See

2.42 RIDER FOOT CONTROLS: XR MODELS

12. See

. Support rear fork (3). Remove rear

fork/engine mount bolts (1) and pull fork assembly from
frame.

sm01818

Bolt (2)

Bearing (2)

Rear fork

Pivot shaft

Frame

Retaining ring

Figure 2-204. Rear Fork Assembly: All Models (XL Shown)

DISASSEMBLY

TOOL NAME

PART NUMBER

BEARING REMOVER/INSTALLER
TOOL

HD-46281

NOTE

See

Figure 2-204

. Remove pivot bearings (2) only if replace-

ment is required.

S e e

F i g u r e 2 - 2 0 5

. U s i n g B E A R I N G

REMOVER/INSTALLER TOOL (Part No. HD-46281) (4,
5, 6), carefully press bearing assemblies from fork bearing
bosses (2):

Place receiver cup (6) on press bed, with recessed
end of cup facing up.

Place rear fork pivot bearing boss (2) over cup as
shown in the photo.

Slide pilot (5) through bearing and into receiver cup.

Insert handle (4) through other rear fork pivot bearing
boss and bearing, down into pilot.

Engage press ram on end of handle and press
bearing out.

Turn rear fork over and press out other pivot bearing in
the same manner.

2-130 2009 Sportster Service: Chassis

sm01465

Rear fork

Pivot bearing boss

Press

Handle

Pilot

Receiver cup

Figure 2-205. Removing Rear Fork Pivot Bearings: All

Models (XL Shown)

CLEANING AND INSPECTION

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 all components in solvent and blow dry with low
pressure compressed air. Carefully inspect bearings for
wear and/or corrosion. Replace bearing assembly if dam-
aged.

. Make sure pivot bearing retaining ring

(6) is not bent or damaged. If it is, replace it with a new
retaining ring. Make sure retaining ring is fully seated in
the groove in each bearing (2).

Check that rear fork (3) is not bent, twisted or cracked.
Replace if damaged.

ASSEMBLY

TOOL NAME

PART NUMBER

BEARING REMOVER/INSTALLER
TOOL

HD-46281

See

. If necessary, press new bearings (2)

into position in rear fork, using BEARING
REMOVER/INSTALLER TOOL (Part No. HD-46281):

Figure 2-206

. Place receiver cup (7) on press

bed, with recessed end of cup facing up.

Place rear fork pivot bearing boss (2) over cup as
shown in the photo.

Place new pivot bearing (6) over pivot bearing boss,
with retaining ring side of bearing up.

Slide pilot (5) through new pivot bearing, through pivot
bearing boss, and into receiver cup.

Insert handle (4) down into pilot.

Engage press ram on end of handle and press
bearing down until retaining ring bottoms out in rear
fork pivot bearing boss.

Turn rear fork over and in the same manner, press in other
pivot bearing into rear fork pivot bearing boss.

INSTALLATION

Slide rear fork assembly into position on motorcycle.

2.15 REAR BRAKE MASTER CYLINDER

. Holding rear fork assembly in position,

install rear fork/engine mount bolts (1). Tighten to 60-70
ft-lbs (81.4-95.0 Nm).

XL models: Position rear brake hose B-clamp and left
passenger footrest bracket in place and install lower
mounting screw. Tighten both mounting screws to 45-50
ft-lbs (61-68 Nm).

XL models: Install rear brake reservoir using screw with
captive washer. Tighten to 20-25 in-lbs (2.3-2.8 Nm).
Place reservoir cover over reservoir and gently press cover
into place. See

RESERVOIR

XR models: Install left and right rider footrests. See

2.42 RIDER FOOT CONTROLS: XR MODELS

Install belt guard and debris deflector. See

2.24 BELT

GUARD AND DEBRIS DEFLECTOR

Install shock absorbers onto rear fork. See

2.26 SHOCK

ABSORBERS

Install rear brake caliper assembly. See

2.16 REAR

BRAKE CALIPER: XL MODELS

2.17 REAR BRAKE

CALIPER: XR MODELS

XR models: Secure rear brake line to left side of fork. See

2.18 BRAKE LINES

10. Install rear wheel and adjust rear belt. See

2.4 WHEELS

11. XL models: install rear exhaust pipe and muffler. See

4.15 EXHAUST SYSTEM: XL MODELS

12. XR models: install exhaust system. See

4.16 EXHAUST

SYSTEM: XR MODELS

1.20 SHOCK ABSORBER ADJUSTMENT

2009 Sportster Service: Chassis 2-131

2.26

SHOCK ABSORBERS

GENERAL

When removing shock absorbers, remove and install one shock
absorber first, then the other. This will eliminate the need to
raise the rear end of the motorcycle. If it is necessary to remove
both shock absorbers at once, place the motorcycle on a suit-
able lift with the rear wheel raised off the ground.

See

for information

on preload adjustment and suspension settings.

NOTE

Except for rubber mounting damper bushings, shock absorbers
are non-repairable items. If the shock absorber is leaking or
damaged, it must be replaced as an assembly.

REMOVAL

If necessary, raise rear end of motorcycle with stand or
suitable blocking underneath frame. If blocking is not
available, remove one shock absorber at a time. The
remaining shock absorber will hold the rear fork and frame
in place.

See

Figure 2-207

. Remove screw (1), washer (7) and lock

nut (9) from bottom end of shock absorber (6) or (15).

Remove screw (2), washer (3) and stud cover (4) (XL
models) from top end of shock absorber.

Remove shock absorber.

If shock absorber is to be replaced, take note of the posi-
tion of the preload setting and adjust the replacement
shock absorber to the same setting.

CLEANING AND INSPECTION

Clean and inspect all parts for wear and damage. Check rubber
components for wear, cracking and stiffness. Examine shock
assembly for signs of leakage. Replace both shock absorbers
as a set if either shock absorber assembly is excessively worn,
leaking or damaged.

INSTALLATION

Figure 2-207

. Install shock absorber upper mounting

screw (2), washer (3), stud cover (4) (XL models) and
shock absorber (6) or (15).

Position bottom end of shock absorber against outboard
side of rear fork mount. Insert screw (1) and washer (7)
through damper bushing (8) and rear fork mount flange.
Install lock nut (9) on end of bolt.

Remove upper mounting screw (2). Apply 2-3 drops of
LOCTITE THREADLOCKER 243 (blue) to threads of upper
mounting screw.

Install washer (3) onto upper mounting screw. Insert screw
through stud cover (4), upper shock absorber damper
bushing (5) and into frame boss. Tighten to 45-50 ft-lbs
(61-68 Nm).

Tighten lower shock absorber mounting screw to 45-50
ft-lbs (61-68 Nm).

If the shock absorber just installed is a replacement, adjust
the preload setting to the same as the original shock
absorber.

2009 Sportster Service: Chassis 2-133

sm01819

Nut

Screw

10.

Screw

Spring adjuster: XL models

11.

Lower spring guide: XL models

Washer

12.

Stud cover: XL models

Upper spring seat: XL models

13.

Shock absorber cover: XL models

Upper bushing: XL models

14.

Shock absorber: XL models

Upper bushing: XR models

15.

Shock absorber: XR models

Washer

Lower bushing

Figure 2-207. Shock Absorber: All Models (Right Side Shown)

2-134 2009 Sportster Service: Chassis

2.27

STABILIZER LINKS

GENERAL

The stabilizer link system allows the engine to "float" on its
rubber engine mounts while maintaining engine-to-frame
alignment. The stabilizer links provide a fixed alignment, and
no adjustment is necessary or possible.

UPPER FRONT STABILIZER LINK

Removal

Position motorcycle upright on suitable lift.

See

. Remove screws (4) and stabilizer link

(2).

Remove upper frame bracket:

Models with front mounted horn: remove screws
(5), washers (8), horn bracket (9), and upper frame
bracket (3) from frame.

Models with side mounted horn: remove screws
(5), washers (8) and upper frame bracket (3) from
frame.

Remove screws (6), lock washers (7) and engine bracket
(1) from front cylinder head.

Installation

See

. Install screws (6), lock washers (7) and

engine bracket (1) to front cylinder head. Tighten to 55-65
ft-lbs (74.6-88.2 Nm).

Install upper frame bracket:

Models with front mounted horn: install upper frame
bracket (3), horn bracket (9), screws (5) and washers
(8).

Models with side mounted horn: install upper frame
bracket (3), screws (5) and washers (8).

Tighten screws to 25-35 ft-lbs (33.9-47.5 Nm).

Install stabilizer link (2). Secure with screws (4). Tighten
to 25-35 ft-lbs (33.9-47.5 Nm).

sm03439

Engine bracket

Upper stabilizer link

Upper frame bracket

Screw

Screw (2)

Lock washer (2)

Washer (2)

Horn bracket (models with front mounted horn)

Figure 2-208. Upper Front Stabilizer Link Assembly:Typical

(XL Model Shown)

LOWER FRONT STABILIZER LINK

Removal

Position motorcycle upright on suitable lift.

. Remove screws (3) and stabilizer link

(1).

Remove screws (4), washers (5) and lower frame bracket
(2) from frame.

Installation

. Install screws (4), washers (5) and lower

frame bracket (2) to frame. Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).

Install stabilizer link (1). Secure with screws (3). Tighten
to 25-35 ft-lbs (33.9-47.5 Nm).

2009 Sportster Service: Chassis 2-135

sm03440

Lower stabilizer link

Lower frame bracket

Screw (2)

Washer (2)

Figure 2-209. Lower Front Stabilizer Link Assembly:Typical

(XL Model Shown)

REAR STABILIZER LINK

Removal

Position motorcycle upright on suitable lift.

California vehicles: remove EVAP canister and mounting
bracket. See

See

. Remove short screw (3), long screw

(4), ground strap (2), stabilizer link (1) and spacer (5).

Installation

See

. Install short screw (3) through ground

strap (2) and stabilizer link (1). Thread screw into frame
on right side of motorcycle. Do not tighten at this time.

Install long screw (4) through ground strap, stabilizer link
and spacer (5) into engine case.

Tighten both screws to 25-35 ft-lbs (33.9-47.5 Nm).

California vehicles: Install EVAP canister and mounting
bracket. See

sm03428

Stabilizer link

Grounding strap

Screw

Spacer

Figure 2-210. Rear Stabilizer Link Assembly: Typical (XL

Model Shown)

2.41 RIDER FOOT CONTROLS: XL

2-136 2009 Sportster Service: Chassis

2.28

FRONT ENGINE MOUNT/ISOLATOR

REMOVAL

TOOL NAME

PART NUMBER

FAT JACK

HD-45968

Position motorcycle upright on a suitable lift.

XL Custom models: Remove both forward foot control
assemblies. See

MODELS EQUIPPED WITH FORWARD CONTROLS

Support front of engine with FAT JACK (Part No. HD-
45968) and suitable blocks.

See

. Remove screw (4) securing upper front

stabilizer link (2) to stabilizer link bracket (3).

See

. Remove screw (3) securing lower front

stabilizer link (1) to stabilizer link bracket (2).

. Remove screw (4) from left end of rear

stabilizer link (1) and ground strap (2). Remove spacer
(5).

NOTE

See

Figure 2-211

. In the next step, the engine may need to be

jacked up or down slightly to aid in removing bolt (3).

See

Figure 2-211

. Remove nut (4) and bolt (3) from front

engine mount/isolator assembly.

Remove screws (5) from front isolator mount (2) on left
side of motorcycle. Remove isolator mount and left front
isolator (1).

Carefully pry front end of engine to the left approximately
1.0 in. (25.4 mm). Remove right front isolator (1) from
crankcase.

sm01823

Isolator (2)

Front isolator mount

Bolt

Nut

Screw (2)

Figure 2-211. Front Engine Mount/Isolator: Typical (XL Model Shown)

2009 Sportster Service: Chassis 2-137

INSTALLATION

TOOL NAME

PART NUMBER

FAT JACK

HD-45968

Figure 2-211

. Install both front isolators (1) in engine

mounting boss on front of crankcase. Note that each isol-
ator has a half-moon tab and fits into engine mounting
boss in only one way. Push engine to the right until right
isolator contacts frame boss.

Install front isolator mount (2) over left front isolator.

Install screws (5) through front isolator mount and thread
into frame. Tighten to 25-35 ft-lbs (33.9-47.5 Nm).

Insert bolt (3) through front isolator/engine mount assembly
from left side. Thread nut (4) onto bolt. Tighten to 60-70
ft-lbs (81.4-95.0 Nm).

. Attach lower front stabilizer link (1) to

bracket (2) with screw (3). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).

See

. Attach upper front stabilizer link (2) to

bracket (3) with screw (4). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).

2.41 RIDER FOOT CONTROLS: XL

. Install screw (4) through free end of

ground strap (2), rear stabilizer link (1), spacer (5), and
into engine crankcase. Tighten to 25-35 ft-lbs (33.9-47.5
Nm).

Remove FAT JACK (Part No. HD-45968) and blocks from
under engine.

XL Custom models: Install both forward foot control
assemblies. See

MODELS EQUIPPED WITH FORWARD CONTROLS

4.16 EXHAUST SYSTEM: XR MODELS

2-138 2009 Sportster Service: Chassis

2.29

REAR ENGINE MOUNT/ISOLATOR

REMOVAL

TOOL NAME

PART NUMBER

SHOP DOLLY

HD-45967

FAT JACK

HD-45968

Remove seat.

Open left side cover. See

2.20 LEFT SIDE COVER

Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)

Disconnect both battery cables, negative cable first. See

1.17 BATTERY MAINTENANCE

Remove exhaust system. See

4.15 EXHAUST SYSTEM:

XL MODELS

With the aid of a FAT JACK (Part No. HD-45968), support
motorcycle on SHOP DOLLY (Part No. HD-45967).

NOTE

Position vehicle on SHOP DOLLY so that FAT JACK may be
used (with the aid of suitable blocks) to support engine when
rear engine mount is removed.

Remove sprocket cover.

XL models: see

Figure 2-212

. Remove screw (6),

washer (5) and exhaust pipe clamp bracket (4).
Remove two screws (2, 3). Remove sprocket cover
(1).

XR models: see

Figure 2-213

. Remove screw and

washer (2) and screws (3, 4). Remove sprocket cover
(1).

Loosen rear axle and remove rear drive belt. See

5.7 DRIVE BELT

XL models equipped with passenger footrests: Remove
left passenger footrest assembly. See

2.43 PASSENGER

FOOTRESTS

XR models: Remove left and right rider controls and
brackets. See

2.42 RIDER FOOT CONTROLS: XR

2.15 REAR BRAKE MASTER CYLINDER RESERVOIR

10. Unbolt rear brake master cylinder remote reservoir. Do

not disconnect hose from reservoir. Secure reservoir to
vehicle in an upright position, out of the way. See

11. Support rear fork assembly using vehicle tiedown straps.

12. See

. Remove rear fork pivot bolts (1).

13. Pull rear fork back far enough to clear rear engine mounts

and isolators.

14. California vehicles: remove EVAP canister and mounting

bracket See

15. See

. Remove screws (3, 4) securing rear

stabilizer link (1). Remove stabilizer link, ground strap (2),
and spacer (5).

16. See

. Remove screw (4) securing upper front

stabilizer link (2) to stabilizer link bracket (3).

17. See

. Remove screw (3) securing lower front

stabilizer link (1) to stabilizer link bracket (2).

18. Support rear of engine with FAT JACK and suitable blocks.

19. See

. Remove two screws (7) securing rear

isolator mount (2) to left side of frame. Remove isolator
mount and left isolator (3).

20. Remove three screws (6) securing rear pivot lockplate (5)

to rear of engine case. Remove lockplate and rear fork
pivot shaft (4).

NOTE

Engine may need to be jacked up or down slightly to aid in
removing pivot shaft.

21. Carefully pry rear end of engine to the left approximately

1.0 in. (25.4 mm). Remove right rear isolator (3) from
frame.

sm01824

Sprocket cover

Screw

Exhaust pipe clamp bracket

Washer

Screw

Figure 2-212. Sprocket Cover: XL Models

2009 Sportster Service: Chassis 2-139

sm05328

Sprocket cover

Rear screw and washer

Front screw

Lower screw

Figure 2-213. Sprocket Cover: XR Models

sm01825

Rear pivot lockplate

Bolt (2)

Rear isolator mount

Screw (3)

Screw (2)

Isolator (2)

Rear fork pivot shaft

Figure 2-214. Rear Engine Mount/Isolator: Typical (XL Model Shown)

2-140 2009 Sportster Service: Chassis

INSTALLATION

TOOL NAME

PART NUMBER

FAT JACK

HD-45968

. Install new right rear isolator (3) into

frame, lining up tabs on isolator with slots in frame. Slide
rear end of engine to the right until engine mounting boss
on rear of crankcase contacts right isolator.

Slide rear fork pivot shaft (4) through engine mounting
boss.

NOTE

Engine may need to be moved slightly in one direction or
another in order to line up pivot shaft with isolator.

Install rear pivot lockplate (5) over pivot shaft with ridges
on lockplate engaging flats on pivot shaft flange. Secure
to crankcase with three screws (6). Tighten to 80-120 in-
lbs (9.0-13.6 Nm).

Install new left rear isolator (3) on rear fork pivot shaft.

Place rear isolator mount (2) over left rear isolator, lining
up tabs on isolator with slots in isolator mount. Install
screws (7). Tighten to 25-35 ft-lbs (33.9-47.5 Nm).

Remove FAT JACK (Part No. HD-45968) and blocks.

See

. Attach upper front stabilizer link (2) to

bracket (3) with screw (4). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).

See

. Attach lower front stabilizer link (1) to

bracket (2) with screw (3). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).

See

. Install short screw (3) through ground

strap (2) and rear stabilizer link (1) into frame on right side
of motorcycle. Install long screw (4) through free end of
ground strap, stabilizer link and spacer (5) into engine
case. Tighten both screws to 25-35 ft-lbs (33.9-47.5 Nm).

10. California vehicles: Install EVAP canister and mounting

bracket. See

11. See

2.15 REAR BRAKE MASTER CYLINDER RESERVOIR

. Slide rear fork forward into position.

Install rear fork pivot/engine mount bolts (1). Tighten to
60-70 ft-lbs (81.4-95.0 Nm). Remove vehicle tiedown
straps supporting rear fork.

12. Install rear brake master cylinder remote reservoir. See

13. XL models equipped with passenger footrests: Install

left passenger footrest assembly. See

2.43 PASSENGER

FOOTRESTS

14. XR models: Install left and right rider foot controls and

brackets. See

2.42 RIDER FOOT CONTROLS: XR

15. Install and adjust rear drive belt and tighten rear axle. See

5.7 DRIVE BELT

16. XL Models: Install sprocket cover.

Figure 2-212

. Install sprocket cover (1). Secure

with two screws (2, 3). Note that long screw goes in
top hole, short screw in bottom hole. Do not tighten
screws at this time.

Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).

17. XR Models: Install sprocket cover.

See

Figure 2-213

. Tighten screw (2) to 30-33 ft-lbs

(40.7-44.7 Nm).

Tighten screws (3, 4) to 80-120 in-lbs (9.0-13.6 Nm).

18. Install exhaust system. See

4.15 EXHAUST SYSTEM: XL

4.16 EXHAUST SYSTEM: XR MODELS

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

19. Connect both battery cables, positive (+) cable first. See

1.17 BATTERY MAINTENANCE

20. Close left side cover. See

2.20 LEFT SIDE COVER

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

21. Install seat.

2009 Sportster Service: Chassis 2-141

2.30

THROTTLE CABLES: ALL MODELS

REMOVAL AND DISASSEMBLY

To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.6 FUEL TANK: XL MODELS

4.7 FUEL TANK: XR