Harley Davidson Sportster Models 2009. Service Repair Manual

2.41

RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS

RIGHT FOOTREST AND REAR BRAKE
PEDAL ASSEMBLY

Removal

NOTE

Right side access is improved by exhaust system removal.
See

4.15 EXHAUST SYSTEM: XL MODELS

See

Figure 2-257

. Remove retaining ring (2), clevis pin

(5), footrest (1) and spring washer (3). Discard retaining
ring.

Remove brake rod (8) from brake pedal (7) and master
cylinder bell crank (14).

Remove retaining ring (16), screw (11) and clevis (4). Slide
brake pedal off clevis. Discard retaining ring.

Remove two screws (9), footrest/brake pedal support
bracket (10) and j-clip (12) from frame (13).

Installation

See

Figure 2-257

. Position j-clip (12) against frame as

shown. Mount footrest/brake pedal support bracket (10)

and j-clip to frame (13) with screws (9). Tighten to 45-50
ft-lbs (61-68 Nm).

Slide brake pedal (7) onto clevis (4). Mount clevis on
footrest/brake pedal support bracket. Line up hole in clevis
with hole in support bracket. Secure with screw (11).
Tighten to 96-156 in-lbs (10.9-17.6 Nm). Install new
retaining ring (16) on end of clevis.

Install footrest (1) on clevis with spring washer (3). Make
sure spring washer is positioned inside clevis with the
square edge toward the inside. Align holes and push clevis
pin (5) from top down through hole in clevis. Secure with
new retaining ring (2).

Apply two drops of LOCTITE THREADLOCKER 243 (blue)
to threads of both brake rod ball stud screws.

Thread one end of brake rod (8) into master cylinder bell
crank (14). Tighten to 120-180 in-lbs (13.6-20.4 Nm).

Thread other end of brake rod into brake pedal. Tighten
to 120-180 in-lbs (13.6-20.4 Nm).

HOME

2009 Sportster Service: Chassis 2-175

sm02207

Screw (2)

Footrest

10.

Retaining ring

Footrest/brake pedal support bracket

11.

Screw

Spring washer

12.

Clevis

J-clip

13.

Frame

Clevis pin

14.

Bushing

Bell crank

15.

Rear brake master cylinder and bracket assembly

Brake pedal

16.

Brake rod assembly

Retaining ring

Figure 2-257. Forward Controls - Brake Side

LEFT FOOTREST AND SHIFT LEVER
ASSEMBLY

Removal

See

Figure 2-258

. Remove retaining ring (13), clevis pin

(17), footrest (16) and spring washer (15). Discard
retaining ring.

Remove screw (21) and shifter peg (18).

Remove shifter rod assembly (4) from shifter lever
assembly (12) and shift lever (3).

Remove retaining ring (20), screw (10) and clevis (14).
Slide shifter lever assembly off clevis. Discard retaining
ring.

Remove two screws (9), footrest/shifter lever support
bracket (8) and j-clip (7) from frame.

Remove pinch screw (1), washer (2), shift lever (3) and
rubber washer (19) from transmission shift shaft.

HOME

2-176 2009 Sportster Service: Chassis

Installation

See

Figure 2-258

. Install rubber washer (19) and shift

lever (3) onto transmission shifter shaft, with shift lever
arm pointing straight down. Secure with pinch screw (1)
and washer (2). Tighten pinch screw to 16-20 ft-lbs (21.7-
27.1 Nm).

Mount j-clip (7) and footrest/shift lever support bracket (8)
to frame with two screws (9). Tighten to 45-50 ft-lbs (61-
68 Nm).

Slide shifter lever assembly (12) onto clevis (14). Mount
clevis on footrest/shifter lever support bracket. Line up
hole in clevis with hole in support bracket. Secure with
screw (10). Tighten to 18-22 ft-lbs (24.4-29.9 Nm). Install
retaining ring (20) on end of clevis.

Mount footrest (16) on clevis with spring washer (15). Make
sure spring washer is positioned inside clevis with the

square edge toward the inside. Align holes and push clevis
pin (17) from top down through hole in clevis. Secure with
new retaining ring (13).

Thread screw (5) in one end of shifter rod assembly (4)
into shift lever (3). Tighten to 120-180 in-lbs (13.6-20.4
Nm).

Thread screw (6) in other end of shifter rod into shift lever
assembly. Tighten to 120-180 in-lbs (13.6-20.4 Nm).

If re-using shifter peg screw (21), clean screw threads and
apply one or two drops of LOCTITE THREADLOCKER
243 (blue) to threads.

NOTE

The previous step is not necessary for a new shifter peg screw
as it has a built-in lock patch.

Install shifter peg (18) and secure with screw (21). Tighten
screw to 96-144 in-lbs (10.9-16.3 Nm)

sm02208

12.

Shifter lever assembly

Pinch screw

13.

Washer

Retaining ring

14.

Clevis

Shift lever

15.

Shifter rod assembly

Spring washer

16.

Footrest

Screw

17.

Screw

Clevis pin

18.

Shifter peg

J-clip

19.

Footrest/shifter lever support bracket

Rubber washer

20.

Retaining ring

Screw (2)

10.

21.

Screw

Screw, shifter peg

11. Bushing

Figure 2-258. Forward Controls - Shifter Side

HOME

2009 Sportster Service: Chassis 2-177

ADJUSTING SHIFT PEDAL

The foot shift linkage is set at the factory and normally should
need no adjustment. However, if gears do not engage fully or
toe shifter travel is incorrect, adjust linkage rod as follows.

See

Figure 2-259

. Adjust shifter rod assembly (4) length until

shifter lever assembly (5) is at 45° as shown in the figure:

Loosen lock nuts (3) on both ends of shifter rod.

Remove screw (1) securing ball joint (2) to shifter lever
assembly.

Turn ball joint or shifter rod to adjust rod length. Tempor-
arily attach ball joint to shifter lever assembly and check
angle. Make sure an equal number of threads are visible
on both ends of shifter rod.

When angle of shift lever assembly is at 45°, install screw
(1). Tighten to 120-180 in-lbs (13.6-20.4 Nm).

Holding shifter rod so that it does not turn, tighten lock
nuts on both ends.

sm01228

Screw (2)

Ball joint (2)

Lock nut (2)

Shifter rod assembly

Shifter lever assembly

Figure 2-259. Adjusting Shift Pedal: Models with Forward

Controls

HOME

2-178 2009 Sportster Service: Chassis

2.42

RIDER FOOT CONTROLS: XR MODELS

RIGHT FOOTREST AND REAR BRAKE
PEDAL ASSEMBLY

Removal

Remove exhaust system. See

4.16 EXHAUST SYSTEM:

XR MODELS

Remove clevis pin connecting master cylinder to brake
pedal. See

2.14 REAR BRAKE MASTER CYLINDER: XR

MODELS

If necesssary, remove wear peg (11).

See

Figure 2-260

. Remove retaining ring (10) and washer

(9). Discard retaining ring.

Remove clevis pin (5), spring (7), and footrest (8).

Remove bolt (3), footrest clevis (6), and brake pedal (4).

If necessary, remove bracket (1). The master cylinder
must be disconnected from the bracket or brake line dis-
connected prior to removing the two fasteners (2). See

2.14 REAR BRAKE MASTER CYLINDER: XR MODELS

sm05342

Master cylinder/footrest bracket

Fastener

Footrest clevis bolt

Brake pedal

Clevis pin

Footrest clevis

Spring

Footrest

Washer

10. Retaining ring
11. Wear peg

Figure 2-260. Rider Foot Control, Right Side: XR Models

Installation

If removed, install master cylinder/footrest bracket. See

2.14 REAR BRAKE MASTER CYLINDER: XR MODELS

See

Figure 2-260

. Install brake pedal on footrest clevis

and install footrest clevis. Tighten bolt (3) to 20-24 ft-lbs
(27.1-32.5 Nm).

Install footrest (8) and spring (7) on clevis and secure with
clevis pin (5). Install washer (9) and new retaining ring
(10).

If removed, install wear peg and tighten to 72-108 in-lbs
(8.1-12.2 Nm).

Connect brake pedal to master cylinder. See

2.14 REAR

BRAKE MASTER CYLINDER: XR MODELS

Install exhaust system. See

4.16 EXHAUST SYSTEM:

XR MODELS

LEFT FOOTREST AND SHIFT LEVER
ASSEMBLY

Removal

See

Figure 2-261

. Remove fasteners (11) and remove

linkage (12).

If necesssary, remove wear peg (9).

Remove retaining ring (4) and washer (5). Discard
retaining ring.

Remove clevis pin (10), spring (7), and footrest (8).

Remove bolt (3), footrest clevis (6), and foot shift lever
(15).

Remove shifter peg (13).

If necessary, remove fasteners (2) and bracket (1).

HOME

2009 Sportster Service: Chassis 2-179

sm05348

Bracket

Fastener (2)

Footrest clevis bolt

Retaining ring

Washer

Footrest clevis

Spring

Footrest

Wear peg

10. Clevis pin
11. Fastener (2)
12. Shift linkage
13. Shifter peg
14. Transmission shift lever
15. Foot shift lever
16. Bushing

Figure 2-261. Rider Foot Control, Left Side: XR Models

Installation

See

Figure 2-261

. If removed, install bracket (1). Tighten

fasteners (2) to 45-50 ft-lbs (61.0-67.8 Nm).

Install foot shift lever on footrest clevis and install footrest
clevis. Tighten bolt (3) to 20-24 ft-lbs (27.1-32.5 Nm).

Install footrest (8) and spring (7) on clevis and secure with
clevis pin (10). Install washer (5) and new retaining ring
(4).

Install shifter peg (13) and tighten to 96-144 in-lbs (10.9-
16.3 Nm).

If removed, install wear peg and tighten to 72-108 in-lbs
(8.1-12.2 Nm).

Connect linkage (12) between foot shift lever (15) and
transmission shift lever (14) using fasteners (11). Tighten
to 120-180 in-lbs (13.6-20.3 Nm).

Check shift linkage adjustment and adjust as necessary.

ADJUSTING SHIFT PEDAL

The foot shift linkage is set at the factory and normally should
need no adjustment. However, if gears do not engage fully or
toe shifter travel is incorrect, adjust linkage rod as follows.

See

Figure 2-262

. Adjust shifter rod assembly (4) length until

shifter lever assembly (5) is at approximately 20° from hori-
zontal as shown in the figure.

Loosen jam nut (3) on front end of shifter rod.

Remove screw (1) securing ball joint (2) to shifter arm (6).

Turn ball joint in one direction or the other to adjust rod
length as necessary. Temporarily attach ball joint to shifter
arm and check angle.

when angle of shift lever assembly is at 20°, install screw
(1). Tighten to 120-180 in-lbs (13.6-20.4 Nm).

Holding ball joint with a wrench on the flats, tighten jam
nut.

sm04910

Screw

Ball joint

Jam nut

Shifter rod

Shifter lever assembly

Shifter arm

20°

Figure 2-262. Adjusting Shift Pedal: XR Models

HOME

2-180 2009 Sportster Service: Chassis

2.43

PASSENGER FOOTRESTS

GENERAL

Passenger footrest assemblies are standard equipment on
certain models only.

XL MODELS

Removal

See

Figure 2-263

. Remove retaining ring (1), clevis pin

(2), footrest (3) and spring washer (4). Discard retaining
ring.

Remove two screws (5) and footrest support bracket (6)
from frame (7).

Installation

NOTE

See

Figure 2-263

. On left side of vehicle, a B-clip (8) is posi-

tioned between footrest support bracket (6) and lower support
bracket hole on frame (7). Make sure this clip is positioned
between footrest support bracket and frame when attaching
support bracket in the next step.

See

Figure 2-263

. Attach footrest support bracket (6) to

frame (7) with two screws (5). Tighten to 45-50 ft-lbs (61-
68 Nm).

Install footrest (3) on footrest support bracket with spring
washer (4). Make sure spring washer is positioned inside
support bracket mounting boss with the square edge
toward the inside.

Align holes and push clevis pin (2) from top down through
hole in support bracket. Secure with new retaining ring
(1).

sm02209

Retaining ring

Clevis pin

Footrest

Spring washer

Screw (2)

Footrest support bracket

Frame

B-clip (left side only)

Figure 2-263. Passenger Footrest Assembly (Not Standard

Equipment on Some Models)

XR MODELS

Removal

See

Figure 2-264

. Remove retaining ring (1), clevis pin

(2), footrest (3) and spring washer (4). Discard retaining
ring.

On right side of vehicle, remove screw (8) securing muffler
bracket (6) to footrest support bracket (7).

Remove two screws (5) and footrest support bracket from
frame.

Installation

See

Figure 2-264

. Attach footrest support bracket (7) to

frame with two screws (5). Tighten to 45-50 ft-lbs (61-68
Nm)).

Attach muffler bracket (6) to footrest support bracket with
screw (8). Tighten to 15-19 ft-lbs (20.4-25.8 Nm).

Install footrest (3) on footrest support bracket with spring
washer (4). Make sure spring washer is positioned inside
support bracket mounting boss with the square edge
toward the inside.

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2009 Sportster Service: Chassis 2-181

Align holes in footrest and support bracket and push clevis
pin (2) from top down through hole in support bracket.
Secure with new retaining ring (1).

sm04920

Retaining ring

Clevis pin

Footrest

Spring washer

Screw (2)

Muffler bracket (right side only)

Footrest support bracket

Screw (right side only)

Figure 2-264. Passenger Footrest Assembly: XR Models

(Right Side Shown)

HOME

2-182 2009 Sportster Service: Chassis

2.44

FORK LOCK

REMOVAL

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

MODELS

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

6.38 MAIN FUSE

Prepare vehicle for fork lock replacement.

All models: remove fuel tank. See

4.6 FUEL TANK:

XL MODELS

4.7 FUEL TANK: XR MODELS

. Turn

front forks fully to the left.

XL 883C/XL 1200C models: remove handlebar upper
clamp/speedometer housing. See

2.32 HANDLE-

BARS

. Secure handlebar assembly out of the way.

See

Figure 2-265

. See

Figure 2-266

. Using a 5/64 in. drill

bit, carefully drill a hole in the center of the lock pin.

NOTE

Take time to carefully orient drill bit to center of lock pin. If drill
bit slides off-center, removal of lock pin will be difficult.

See

Figure 2-267

. To remove lock pin, insert a screw

extractor into the 5/64 in. hole. Hold body of screw
extractor with a pliers or tap handle and using a small
hammer gently "tap" on the pliers or tap handle to remove
lock pin.

Remove lock assembly.

sm01230

Figure 2-265. Fork Lock Pin

sm01231

Figure 2-266. Drilling Lock Pin

sm01232

Figure 2-267. Removing Lock Pin

INSTALLATION

Insert new lock assembly in frame lock housing.

Align lock pin hole in new lock assembly with hole in the
frame lock housing.

Drive new lock pin in position (flush with frame lock
housing).

HOME

2009 Sportster Service: Chassis 2-183

Reassemble motorcycle.

XL 883C/XL 1200C models: Install handlebar
assembly and upper clamp/speedometer housing.
See

2.32 HANDLEBARS

All models: install fuel tank. See

4.6 FUEL TANK:

XL MODELS

4.7 FUEL TANK: XR MODELS

Verify proper operation of fork lock.

Turn front forks fully to the left.

Insert key into fork lock. Turn key 90 degrees clock-
wise.

Verify that front forks are locked and cannot be turned.

Turn key 90 degrees counterclockwise and remove
from fork lock.

Verify that front forks are now free to fully turn right
and left.

Plug in main fuse. See

6.38 MAIN FUSE

HOME

2-184 2009 Sportster Service: Chassis

3.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Tappets

9.0-12.4 Nm

80-110 in-lbs

Anti-rotation device mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

129-142 Nm

95-105 ft-lbs

Axle nut, rear

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

129-142 Nm

95-105 ft-lbs

Axle nut, rear

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

3.4-4.5 Nm

30-40 in-lbs

Brake (rear) hose clamp-to-frame screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

2.3-2.8 Nm

20-25 in-lbs

Brake rear master cylinder reservoir
mounting screw

3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers

4.0-6.2 Nm

35-55 in-lbs

Breather screw

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase

20.3-25.8 Nm

15-19 ft-lbs

Crankcase fastener

3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure

11-14 Nm

96-120 in-lbs

Cylinder head bolts

3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure

18-20 Nm

13-15 ft-lbs

Cylinder head bolts

3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure

11-14 Nm

96-120 in-lbs

Cylinder head bolts

3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure

18-20 Nm

13-15 ft-lbs

Cylinder head bolts

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

23.1-32.6 Nm

17-24 ft-lbs

Cylinder head bracket screw

3.16 TOP END OVERHAUL:
ASSEMBLY, Assembling Motorcycle After Top End
Repair

23.1-32.6 Nm

17-24 ft-lbs

Cylinder head bracket screw

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Feed Assembly

29.8-35.3 Nm

22-26 ft-lbs

Cylinder head oil feed flare fitting, Preci-
sion Cooling

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Feed Assembly

17.6-23.0 Nm

13-17 ft-lbs

Cylinder head oil feed line flare nut,
Precision Cooling

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase

13.6-27.1 Nm

120-240 in-lbs

Cylinder stud

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

61.0-67.8 Nm

45-50 ft-lbs

Footrest bracket fastener

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

61.0-67.8 Nm

45-50 ft-lb

Footrest mount fastener

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Return Lines

9.5-12.2 Nm

84-108 in-lbs

Front cylinder oil line retainer nut

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

81.4-95.0 Nm

60-70 ft-lbs

Front engine mount bolt

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

81.4-95.0 Nm

60-70 ft-lbs

Front engine mount bolt

HOME

2009 Sportster Service: Engine 3-1

sm01531

Figure 3-132. Valve Guide Seal Protector Sleeve

NOTES

•

Always use a protective sleeve on the valve stem keeper
groove when installing valve stem seal. If the seal is
installed without using the protective sleeve, the seal will
be damaged, causing leakage around the valve stem,
excessive oil consumption and valve sticking.

•

See

Figure 3-133

. The valve seal is incorporated into the

lower valve collar and is installed by hand. NO SPECIAL
TOOLS ARE REQUIRED.

•

The valve seal is completely installed when the lower valve
collar contacts the machined surface of the head.

sm01534

Figure 3-133. Valve Seal and Lower Valve Collar Assembly

(seal and lower collar replaced as assembly only)

sm01536

Figure 3-134. Valve Seal and Lower Valve Collar Assembly

Installation

See

Figure 3-134

. Place a new seal and lower valve collar

assembly over valve stem and onto valve guide.

NOTES

•

Do not remove valve after seal is installed. Otherwise,
sharp edges on keeper groove will damage seal.

•

A single valve spring is used for each valve. The inner and
outer springs are combined into one progressively wound,
tapered spring.

See

Figure 3-131

. Install valve spring (5) and upper collar

(4).

See

Figure 3-135

. Compress valve spring with VALVE

SPRING COMPRESSOR (Part No. HD-34736-B).

See

Figure 3-131

. Insert valve collar retainers (3) into

upper collar (4), making sure they engage groove in valve
stem. The retainer gaps should be equal.

Release and remove VALVE SPRING COMPRESSOR.

Repeat previous steps for remaining valve(s).

10. Install stabilizer link bracket (16) to front head with two

screws (17) and lock washers (18). Tighten to 55-65 ft-lbs
(74.6-88.2 Nm).

HOME

3-112 2009 Sportster Service: Engine

3.22

CYLINDER AND PISTON

REMOVAL AND DISASSEMBLY

See

3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder

and Piston

to remove cylinder and piston from engine.

CLEANING, INSPECTION AND REPAIR

TOOL NAME

PART NUMBER

TORQUE PLATE BOLTS

HD-33446-86

CYLINDER TORQUE PLATES

HD-33446-B

Soak cylinder and piston in an aluminum-compatible
cleaner/solvent until deposits are soft, then clean with a
brush. Blow off loosened carbon and dirt particles and
wash in solvent.

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 oil passage in cylinder with low pressure com-
pressed air.

Clean piston ring grooves with a piece of compression
ring ground to a chisel shape.

Examine piston pin to see that it is not pitted or scored.

Check piston pin bushing to see that it is not loose in
connecting rod, grooved, pitted or scored.

A piston pin properly fitted to upper connecting rod
bushing has a 0.00125-0.00175 in. (0.0317-0.0444
mm) clearance in bushing.

If piston pin-to-bushing clearance exceeds 0.002 in.
(0.0508 mm), replace worn parts. See

3.22 CYL-

INDER AND PISTON, Connecting Rod Bushings

Clean piston pin lock ring grooves.

Examine piston and cylinder for cracks, burnt spots,
grooves and gouges.

NOTE

Check connecting rod for up and down play in lower bearings.
When up and down play is detected, flywheel and connecting
rod assembly must be replaced. This requires removing and
disassembling engine crankcase.

Checking Gasket Surface

NOTE

If either cylinder gasket surface does not meet flatness specific-
ations, replace cylinder and piston.

See

Figure 3-136

. Check that cylinder top (head) gasket

surface is flat within 0.006 in. (0.15 mm). Lay a straight
edge across the surface, then try to insert a feeler gauge
between the straightedge and the gasket surface.

Check that the cylinder base gasket surface is flat within
0.008 in. (0.20 mm). Lay a straightedge across the surface,
then try to insert a feeler gauge between the straightedge
and the gasket surface.

sm01539

Figure 3-136. Checking Gasket Surfaces

Measuring Cylinder Bore

See

Figure 3-137

. Remove any burrs from the cylinder

gasket surfaces.

Install a head and base gasket, and CYLINDER TORQUE
PLATES (Part No. HD-33446-B) and TORQUE PLATE
BOLTS (Part No. HD-33446-86) . Tighten the bolts using
the same method used when installing the cylinder head
screws. See

3.21 CYLINDER HEAD, Installation

NOTE

Torque plates, properly tightened and installed with gaskets,
simulate engine operating conditions. Measurements will vary
as much as 0.001 in. (0.025 mm) without torque plates.

Take cylinder bore measurement in ring path, starting
about 1/2 in. (13 mm) from top of cylinder, measuring from
front to rear, and then side to side. Record readings.

Repeat measurement at center, and then at bottom of ring
path. Record readings. This process will determine if cyl-
inder is out-of-round (or "egged") and will also show any
cylinder taper or bulge. Refer to

Table 3-34

. If cylinder is

not scuffed or scored and is within service limit, see

3.22 CYLINDER AND PISTON

HOME

3-114 2009 Sportster Service: Engine

Harley Davidson Sportster Models 2009. Service Repair Manual - page 28