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Harley Davidson Sportster Models 2009. Service Repair Manual - page 29

Table 3-34. Cylinder Bore Service Wear Limits

1200 CC

883 CC

BORE SIZE

3.5008 in. (88.920 mm)

3.0035 in. (76.289 mm)

Standard bore

3.5050 in. (89.027 mm)

3.0078 in. (76.398 mm)

0.005 in. (0.13 mm) OS bore

3.5100 in. (89.154 mm)

3.0128 in. (76.525 mm)

0.010 in. (0.25 mm) OS bore

XR 1200 Models: Oversized pistons are not available. Replace piston and/or cylinder if exceeds wear limits.

NOTE

If piston clearance exceeds service limit, cylinders should be
re-bored and/or honed to next standard oversize, and refitted
with the corresponding piston and rings. Do not fit piston tighter
than 0.0007 in. (0.018 mm). See

3.2 SPECIFICATIONS

sm01540

Figure 3-137. Measuring Cylinder Bore

Measuring Piston to Cylinder Fit

NOTE

This inspection is very heat sensitive. Do not check piston
running clearance immediately after honing or deglazing cyl-
inder. Even holding the piston in your hand for too long can
cause measurements to vary by as much as 0.002 in. (0.051
mm). Both piston and cylinder must be at room temperatures
before proceeding.

Measure the piston running clearance. Proceed as follows:

NOTE

Check the piston clearance in the cylinder in which the piston
will run. The torque plates must be installed on the cylinder to
simulate an assembled cylinder for accurate measurement of
cylinder.

sm01543

Figure 3-138. Measurement Area (typical; XL model shown)

See

Figure 3-138

. the measurement is taken on bare

aluminum to avoid measuring errors. An oval-shaped
opening in the coating is present on each side of the piston
for proper placement of the micrometer.

sm01545

4-5 inch micrometer

Spherical ball anvil adapter (2)

Figure 3-139. Micrometer with Anvil Adapters

NOTE

The oval openings are too small for a standard flat anvil
micrometer. Using such a device would result in measuring
errors. See

Figure 3-139

. Use a 3-4 inch blade or ball anvil

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2009 Sportster Service: Engine 3-115

style micrometer, or a 4-5 inch micrometer with spherical ball
anvil adapters.

Measure the piston skirt at the oval openings and then
transfer that measurement to a dial bore gauge.

Using a grease pencil, mark the top, middle and bottom
of the piston ring travel zone in the cylinder bore. Measure

at markings in cylinder parallel and perpendicular to
crankshaft.

Replace piston and/or cylinder if running clearance
exceeds 0.003 in. (0.076 mm).

Boring and Honing Cylinder

Table 3-35. Cylinder Final Bore Sizes

1200 CC

883 CC

BORE SIZE

IN.

88.844

3.4978

76.213

3.0005

Standard bore*

88.95

3.502

76.323

3.0048

0.005 in. (0.13 mm) OS bore

89.08

3.507

76.449

3.0098

0.010 in. (0.25 mm) OS bore

* All bore sizes + 0.0002 in. (0.00508 mm)

XR 1200 Models: Oversized pistons are not available. Replace piston and/or cylinder if exceeds wear limits.

The cylinder must be bored with gaskets and torque plates
attached. Bore the cylinder to 0.003 in. (0.08 mm) under
the desired finished size.

Hone the cylinder to its finished size using a 280 grit rigid
hone followed by a 240 grit flexible ball hone. Honing must
be done with the torque plates attached. All honing must
be done from the bottom (crankcase) end of the cylinder.
Work for a 60° crosshatch pattern.

See

Table 3-35

for final cylinder bore sizes after honing.

NOTES

•

When cylinder requires oversize re-boring to beyond 0.010
in. (0.25 mm), the oversize limit has been exceeded and
cylinder must be replaced.

•

The same piston may be used if cylinder bore was not
changed, unless it is scuffed or grooved. However, replace
rings and hone the cylinder walls with a No. 240 grit flexible
ball hone.

Failure to remove all abrasive particles may result in pre-
mature cylinder, piston and ring wear and engine failure.
(00537b) .

Thoroughly wash the cylinder bore with liquid dishwashing
soap and warm water to remove all abrasive particles and
residual grit. Continue cleaning until a clean cloth shows
no remaining dirt or debris.

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)

Hot rinse the cylinder and dry with moisture free low
pressure compressed air.

Immediately apply a thin film of clean engine oil to a clean
white paper towel and thoroughly wipe the inside of the
cylinder.

NOTE

After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
remains white. The cylinder is now clean.

With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run.

Fitting Piston Rings

See

Figure 3-140

. Piston rings are of two types: compression

and oil control. The two compression rings are positioned in
the two upper piston ring grooves. The dot on the second
compression ring must face upward. Ring sets are available
to fit standard and oversize pistons.

Piston ring sets must be properly fitted to piston and cylinder:

See

Figure 3-141

. Place piston in cylinder about 1/2 in.

(13 mm) from top. Set ring to be checked inside cylinder,
squarely against piston. Remove piston and check ring
end gap with thickness gauge. See

3.2 SPECIFICATIONS

for tolerance.

NOTE

See piston ring gap Service Wear Limits in

3.2 SPECIFICA-

TIONS

for end gap dimensions. Do not file rings to obtain

proper gap.

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3-116 2009 Sportster Service: Engine

sm01598

Top ring - Install either side up

Second ring - Install dot toward top

Oil control rings

Figure 3-140. Piston Rings

sm01548

Figure 3-141. Measuring Ring End Gap

Use low pressure compressed air to remove any dirt or
dust that may have settled in piston oil drain holes and
ring grooves. Apply clean engine oil to piston ring grooves.

See

Figure 3-142

. Install oil control ring expander spring.

Make sure ends of spring point upward. Spiral bottom oil
control ring into space in ring groove below expander
spring. Position oil control ring gap 90° from gap in
expander spring. Spiral top oil control ring into space in
ring groove above expander spring. Position oil control
ring gap 180° from gap in bottom oil control ring

sm01553

Figure 3-142. Installing Oil Control Ring Expander Spring

(typical; XL model shown)

See

Figure 3-143

. Use a piston ring expander tool to slip

compression rings over piston into their respective
grooves. Install second compression ring first, then top
compression ring. Be extremely careful not to over expand
or twist rings, or damage piston surface when installing
rings.

NOTE

Install second compression ring with dot towards top of piston.

sm01554

Figure 3-143. Installing Piston Rings (typical; XL model

shown)

See

Figure 3-144

. Position rings so end gaps of adjacent

rings are a minimum of 90° apart. Ring gaps are not to be
within 10° of the thrust face centerline.

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2009 Sportster Service: Engine 3-117

See

Figure 3-145

. Check for proper side clearance with

thickness gauge, as shown. See

3.2 SPECIFICATIONS

for tolerance.

NOTE

If the ring grooves are clean, and the side play is still not cor-
rect, replace the rings, the piston, or both.

sm01555

Front

Rear

Piston Pin

Figure 3-144. Position Ring End Gaps at Arrows

sm1556

Figure 3-145. Measuring Ring Clearance in Groove (typical;

XL model shown)

CONNECTING ROD BUSHINGS

TOOL NAME

PART NUMBER

WRIST PIN BUSHING HONE

HD-35102

REAMER LUBRICANT

HD-39964

CONNECTING ROD BUSHING
REAMER

HD-94800-26A

CONNECTING ROD CLAMPING TOOL

HD-95952-33C

CONNECTING ROD BUSHING
REMOVER/INSTALLER

HD-95970-32D

Removing Upper Connecting Rod Bushings

NOTES

•

Replace the upper connecting rod bushing if the piston
pin to rod bushing clearance exceeds 0.002 in. (0.051
mm).

•

Place clean shop towels in and around the crankcase bore
to prevent chips and shavings from falling into the crank-
case.

•

If CONNECTING ROD CLAMPING TOOL (Part No. HD-
95952-33C) holes are too small, enlarge the holes in the
tool.

See

Figure 3-146

. Obtain the CONNECTING ROD

CLAMPING TOOL and install as follows:

Slide clamp (2) over connecting rod so that slots
engage cylinder head studs. Exercise caution to avoid
scratching or bending studs.

With the knurled side up, screw threaded cylinders
(1) onto studs to secure position of clamp.

Alternately turn each clamp thumbscrew (3) a few
turns to gradually fix position of connecting rod.
Turning only one thumbscrew will move rod off-center,
while tightening second thumbscrew can cause rod
to flex or bend.

Install rubber hoses over remaining two cylinder studs.

See

Figure 3-147

. Obtain the CONNECTING ROD

BUSHING REMOVER/INSTALLER (Part No. HD-95970-
32D).

Sparingly apply graphite lubricant to threads of bolt
(6) to prolong service life and ensure smooth opera-
tion.

Slide receiver cup (5) onto bolt with the closed side
facing bolt head.

Insert bolt through upper connecting rod bushing.

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3-118 2009 Sportster Service: Engine

sm01557

Threaded cylinder (2)

Clamp

Thumb screw (2)

Figure 3-146. Connecting Rod Clamping Tool (Part No.

HD-95952-33C)

sm01558

Nut

Flat washer

Nice bearing

Remover/Installer

Receiver cup

Bolt

Figure 3-147. Connecting Rod Bushing Remover/Installer

(Part No. HD-95970-32D)

Remove bushing as follows:

See

Figure 3-148

. Slide remover side of

remover/installer onto bolt. The driver is stamped to
ensure proper orientation.

See

Figure 3-147

. Slide Nice bearing (3) and flat

washer (2) onto bolt (6) until they contact
remover/installer (4).

Thread nut (1) onto bolt until assembly is snug.

Using two box end wrenches, tighten nut on bolt until
bushing is free.

Remove nut from bolt. Remove flat washer, Nice
bearing and remover/installer. Remove bolt from
bushing bore.

Remove bushing from receiver cup and discard.

NOTE

Leave CONNECTING ROD CLAMPING TOOL installed during
bushing installation procedure which follows.

sm01559

Figure 3-148. Remover Stackup. Use Remover Side Of

Remover/Installer

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2009 Sportster Service: Engine 3-119

Installing Upper Connecting Rod Bushings

See

Figure 3-147

. Obtain the CONNECTING ROD

BUSHING REMOVER/INSTALLER (Part No. HD-95970-
32D).

Sparingly apply graphite lubricant to threads of bolt
(6) to prolong service life and ensure smooth opera-
tion.

Slide receiver cup (5) onto bolt with the closed side
facing bolt head.

Insert bolt through upper connecting rod bushing bore.

See

Figure 3-149

. Slide new bushing onto bolt. Start

bushing into bore. Verify that center of slot in bushing
(2) is aligned with oil hole in connecting rod (3). Also,
be sure that bushing is square in bore and not cocked.

Slide installer side of remover/installer (1) onto bolt
until shoulder contacts bushing. The remover/installer
is stamped to ensure proper orientation.

See

Figure 3-147

. Slide Nice bearing (3) and flat

washer (2) onto bolt until they contact
remover/installer.

Thread nut (1) onto bolt until assembly is snug.

Using two box end wrenches, tighten nut on bolt until
collar on remover/installer bottoms against connecting
rod. See

Figure 3-150

Remove nut from bolt and remove flat washer, Nice
bearing and remover/installer. Remove bolt from bushing
bore, but exercise caution to avoid scratching or gouging
bushing.

NOTE

Leave CONNECTING ROD CLAMPING TOOL installed during
bushing reaming procedure which follows.

sm01573

Installer side of remover/installer

Slot in bushing

Oil hole in connecting rod

Figure 3-149. Installer Stackup

sm01575

Piston bushing tool

Rod clamping fixture

Figure 3-150. Installing New Piston Pin Bushing

Reaming Upper Connecting Rod Bushings

NOTE

Sizing bushing with less than 0.00125 in. (0.0317 mm) clear-
ance can result in a bushing loosening and/or seized pin in
rod.

Clean up and size bushing to 0.0010-0.0005 in. (0.025-
0.013 mm) undersize using the CONNECTING ROD
BUSHING REAMER (Part No. HD-94800-26A) .

Carefully insert bit of reamer into upper connecting
rod bushing. Do not apply lubricant to reamer or
bushing. Ream the bushing dry or cut will not be
accurate.

Install a 11/16-inch 12-pt socket and T-handle on
reamer lug.

Placing thumb on drive socket, apply slight pressure
on reamer while rotating handle/drive socket in a
clockwise direction.

NOTE

For best results, do not push on reamer or apply pressure
to the reamer handle. While excessive pressure results in
a rough cut, bushing bore will be tapered if pressure is not
centrally applied.

Continue rotating handle/drive socket until entire bit
has passed through bushing and shank of reamer
rotates freely in the bore.

NOTE

Never back reamer out of connecting rod or bushing will be
damaged.

Remove T-handle and socket, and carefully pulling on bit,
draw shaft of reamer out of connecting rod bushing.

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3-120 2009 Sportster Service: Engine

NOTE

Abrasive particles can damage machined surfaces and plug
oil passageways possibly resulting in engine failure.

Using contact cleaner or cleaning solvent, thoroughly wipe
upper connecting rod and bushing of any metal shavings
or debris.

NOTE

Leave CONNECTING ROD CLAMPING TOOL installed during
bushing honing procedure which follows.

Honing Upper Connecting Rod Bushings

Obtain the WRIST PIN BUSHING HONE (Part No. HD-
35102) and REAMER LUBRICANT (Part No. HD-39964)
to hone bushing to final size. Use a liberal amount of
honing oil to prevent damage to hone or bushing. Use
care to prevent foreign material from falling into the
crankcase.

Install hone in a high speed electric drill.

Apply reamer lubricant to finishing stones of hone and
inside of upper connecting rod bushing.

Start finishing stones of hone into bushing.

Activating the drill, move the entire length of the fin-
ishing stone arrangement forward and backward
through the bushing bore for 10 to 12 complete
strokes. Work for a crosshatch pattern of approxim-
ately 60°.

NOTE

Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine failure.

Using contact cleaner or cleaning solvent, thoroughly wipe
upper connecting rod and bushing of any metal shavings
or debris. Continue wiping until a clean cloth shows no
evidence of dirt or debris.

Lightly oil a good piston pin and insert it into the upper
connecting rod bushing bore to feel for the proper interfer-
ence fit. The pin should slide in and out of the bushing
without binding, but also without pivoting or rocking.

Remove CONNECTING ROD CLAMPING TOOL.

Remove shop towels exercising caution that shavings,
chips and other debris do not fall into crankcase.

Repair

If connecting rod is bent, do not attempt to straighten. Flywheel
and connecting rod assembly must be replaced. Straightening
connecting rods by bending will damage the bearing on the
crank pin and the piston pin bushing.

ASSEMBLY AND INSTALLATION

See

3.16 TOP END OVERHAUL: ASSEMBLY, Piston and

Cylinder

to install piston and cylinder onto engine.

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2009 Sportster Service: Engine 3-121

3.23

CRANKCASE

GENERAL

When connecting rod and flywheel assembly, pinion shaft
bearing, or sprocket shaft bearing are in need of replacement,
it is recommended procedure to check and make repairs to
cylinder heads, cylinders, gear case and transmission at the
same time (perform entire engine overhaul).

NOTE

When engine is removed from chassis, do not lay engine on
primary side. Laying engine on primary side will damage the
clutch cable end fitting. If fitting is damaged, clutch cable must
be replaced.

sm03411

Retaining ring

Sprocket shaft spacer

Retaining ring

Connecting rod and flywheel assembly

Pinion shaft bearing

Left main oil seal

10.

Thrust washer

Retaining ring

11.

Outer bearing race

Left crankcase

12.

Left main bearing

Right crankcase

Figure 3-151. Crankcase and Flywheel Assembly (typical; XL model shown)

REMOVAL

Remove engine from motorcycle. See

3.12 REMOVING

ENGINE FROM CHASSIS

Disassemble top end of engine. See

3.15 TOP END

OVERHAUL: DISASSEMBLY, Cylinder Heads

and

3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder
and Piston

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3-122 2009 Sportster Service: Engine

DISASSEMBLY

TOOL NAME

PART NUMBER

CRANKCASE BEARING
REMOVER/INSTALLER WITH
ADAPTER

B-45655, HD-42720-
2, HD-46663

END CAP

HD-34902-7

BEARING RACE REMOVER AND
INSTALLER KIT

HD-34902-C

FLYWHEEL SUPPORT FIXTURE

HD-44358

CLAW PULLER WEDGE ATTACH-
MENT

HD-95637-46B

TRANSMISSION SHAFT RETAINING
RING PLIERS

J-5586-A

Disassemble crankcase, see

3.17 BOTTOM END OVER-

HAUL: DISASSEMBLY, Crankcase

NOTE

See

Figure 3-151

. If it is necessary to remove either the pinion

shaft bearing (9) or left main bearing (6), proceed as follows:

See

Figure 3-152

. Pinion shaft bearing assembly (3) will

remain on pinion shaft (2) when flywheel assembly (1) is
removed from right crankcase. Using TRANSMISSION
SHAFT RETAINING RING PLIERS (Part No. J-5586-A),
remove retaining ring (4) and slip bearing off pinion shaft.

sm01488

Flywheel assembly

Pinion shaft

Pinion shaft bearing assembly

Retaining ring

Figure 3-152. Removing Pinion Shaft Bearing Retaining

Ring

See

Figure 3-153

. Place flywheel assembly in FLYWHEEL

SUPPORT FIXTURE (Part No. HD-44358). Pull sprocket
shaft bearing inner race with CLAW PULLER WEDGE
ATTACHMENT (Part No. HD-95637-46B) with BEARING
RACE REMOVER AND INSTALLER KIT (Part No. HD-
34902-C) and END CAP (Part No. HD-34902-7).

NOTE

The sprocket shaft inner race is not replaceable. If it is worn
or damaged, the crankshaft assembly must be replaced.

See

Figure 3-153

. See

Figure 3-151

. Remove outer left

main bearing retaining ring (2).

See

Figure 3-151

. Remove left main oil seal (3) from left

crankcase using Snap-On Tool (Part No. CJ 114, Body
Dent Puller).

Remove thrust washer (4) next to left main bearing (6).

sm01491

Figure 3-153. Removing Left Main Oil Seal Retaining Ring

See

Figure 3-154

and

Figure 3-151

. Remove left main

bearing retaining ring (7) from the inside of the left crank-
case (5).

NOTE

When removing the left main bearing, the bearing presses from
the outside of the left crankcase toward the inside. A shoulder
is incorporated into the left crankcase which allows the bearing
to be removed in one direction only.

See

Figure 3-155

. Using CRANKCASE BEARING

REMOVER/INSTALLER WITH ADAPTER (Part No. B-
45655, HD-42720-2, HD-46663) press left main bearing
out of the left crankcase.

Place support tube (1) on press bed with recessed
cup end facing up.

With the outboard side of the left crankcase (2) facing
upward, position crankshaft bearing bore (3) over
support tube.

Place adapter (4) over left main bearing. Insert
pilot/driver (5) through adapter, through left main
bearing and into support tube.

Carefully apply pressure with press ram (6) until left
main bearing drops free.

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2009 Sportster Service: Engine 3-123

sm01493

Figure 3-154. Removing Left Main Bearing Retaining Ring

sm01494

Support tube

Left crankcase

Crankshaft bearing bore

Adapter

Pilot/driver

Press ram

Figure 3-155. Removing Left Main Bearing from Crankcase

FITTING PINION BEARINGS

TOOL NAME

PART NUMBER

END CAP

HD-34902-7

FORCING SCREW

J-21686-12

BRIDGE

J-7830-5

BEARING SEPARATOR

SNAP-ON TOOLS
STOCK NO. CJ950

See

Figure 3-151

. The outer race (11) is a pressed-in bushing

in the right crankcase. The inner race is pressed on the pinion
shaft.

See

Figure 3-156

. To remove pinion shaft inner race, use

BEARING SEPARATOR (Part No. Snap-on Tools Stock No.
CJ950), three items from END CAP (Part No. HD-34902-7),
BRIDGE (Part No. J-7830-5) and FORCING SCREW (Part
No. J-21686-12), and two bolts. Apply heat to race to aid
removal. Four sizes of pinion bearings are available.

sm01495

Forcing screw

Bridge

End cap

Bolts (2)

Bearing separator

Flywheel support fixture

Figure 3-156. Pulling Pinion Shaft Inner Bearing

Pinion bearing selection at the factory, during engine rebuild,
or replacement of crankcase set or flywheel assembly, is based
on the largest measured outside diameter (O.D.) of the inner
race and the smallest measured inside diameter (I.D.) of the
outer race (crankcase bushing).

A running clearance of 0.0002-0.0008 in. (0.005-0.020 mm) is
established during crankcase set or flywheel assembly
replacement and engine rebuild.

See

Figure 3-157

. Installed inner races are identified at the

factory as shown.

See

Figure 3-158

. Outer races are identified at the factory as

shown.

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3-124 2009 Sportster Service: Engine

sm01497

Paint dot

Inner race

Figure 3-157. Factory Inner Race Sizes

NOTE

The different sizes of crankcase sets and flywheel assemblies
will not have separate part numbers. That is, a replacement
crankcase set may have a class 1, 2 or 3 pinion outer race.
Replacement flywheel assemblies will have either a class A or
B inner race.

See

Figure 3-159

. Pinion bearings are identified as shown.

Bearing Selection

Select bearings using the identification information given for
inner and outer races and bearings. Refer to

Table 3-39

NOTE

If either inner or outer race show wear, measure both races to
confirm correct bearing fit of 0.0002-0.0008 in. (0.005-0.020
mm). The service wear limit of the outer race I.D. is 1.5672 in.
(39.807 mm).

Table 3-36. Inner Race Specifications

IDENTIFICATION*

CLASS

RACE O.D.

IN.

White

31.745-31.750

1.2498-1.2500

Green

31.740-31.745

1.2496-1.2498

* Paint dot on end of spline.

Table 3-37. Roller Specifications

IDENTIFICATION (PACKAGE

COLOR)

ROLLER O.D. (A)

Red

Largest

Blue

White (Grey)

Green

Smallest

Table 3-38. Outer Race Specifications

STAMPED IDENTIFICATION*

CLASS NO.

RACE I.D.

IN.

39.741-39-746

1.5646-1.5648

39.746-39.751

1.5648-1.5650

39.751-39.756

1.5650-1.5652

* Stamped number inside crankcase near race.

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2009 Sportster Service: Engine 3-125

sm03412

Outer race

Stamped class no.

Right crankcase

Figure 3-158. Factory Outer Race Sizes

sm03413

A - Roller O.D. cannot be measured to required
accuracy with micrometer

Figure 3-159. Bearing Identification

Table 3-39. Pinion Shaft Bearing Selection

BEARING SIZE AS IDENTIFIED BY COLOR CODING

OUTER RACE I.D.

FACTORY

STAMPED

NUMBER

Service Wear Limit Exceeded - Replace Outer Race and Resize

over

1.5658 in. (39.771 mm)

Blue

Red

1.5656-1.5658 in.

(39.766-39.771 mm)

White-Gray

Blue

Red

1.5654-1.5656 in.

(39.761-39.766 mm)

Green

White-Gray

Blue

Red

1.5652-1.5654 in.

(39.756-39.761 mm)

Green

White-Gray

Blue

Red

1.5650-1.5652 in.

(39.751-39.756 mm)

Green

White-Gray

Blue

1.5648-1.5650 in.

(39.746-39.751 mm)

Green

White-Gray

1.5646-1.5648 in.

(39.741-39.746 mm)

1.2504-1.2506

1.2502-1.2504

1.2500-1.2502

1.2498-1.2500

1.2496-1.2498

Inner Race O.D. (in.)

31.760-31.765

31.755-31.760

31.750-31.755

31.745-31.750

31.740-31.745

Inner Race O.D. (mm)

White

Green

Factory Color Code

NOTE

Removal and installation of the inner and outer bearing races
require the use of shop-made tools. Dimensions for fabricating
the tools are shown in

. Measure I.D. of outer race at four places

with a dial bore gauge. Take measurement on I.D. where
bearing rollers ride. Record the four measurements.

Table 3-40. Used Pinion Bearing Outer Race Specifications

SPECIFICATION

ITEM

1.5672 in. (39.807 mm)

Largest I.D. allowed

within 0.0002 in. (0.005 mm)

Roundness of I.D.

within 0.0002 in. (0.005 mm)

Taper

If the largest measurement is larger than 1.5672 in.
(39.807 mm) or the required lapping to remove wear marks
would enlarge bore beyond 1.5672 in. (39.807 mm), con-
tinue at Step 8.

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3-126 2009 Sportster Service: Engine

If the largest measurement is 1.5672 in. (39.807 mm) or
less, cover the cam bearings with masking tape to prevent
debris from entering bearings. Assemble crankcase halves.

NOTE

The next step requires lapping the outer race. To keep sprocket
shaft and pinion shaft bearings aligned, the lap must be sup-
ported by an adaptor or pilot in the left crankcase.

Lap the outer race. See

3.23 CRANKCASE, Lapping

Engine Main Bearing Races

. The race must be lapped

until all wear marks are removed.

After lapping race, again measure I.D. of race at four
places and record the measurements.

Check measurements against the specifications listed in

Table 3-40

If lapping increased bore I.D. to larger than 1.5672 in.
(39.807 mm), go to next step. If roundness or taper do not
meet specifications, continue lapping until specifications
are met. If all specifications are met, continue at Step 10
to remove and size inner race.

NOTE

Always use the smallest outer race I.D. measurement and the
largest O.D. inner race measurement when selecting bearings.

Press the outer race from the right crankcase. Press new
outer race into crankcase flush with inside edge of cast-in
insert.

The new outer race must be lapped slightly to true and
align with left case bearing, and to meet the specifications
in

Table 3-41

. See

3.23 CRANKCASE, Lapping Engine

Main Bearing Races

Table 3-41. New Pinion Bearing Outer Race Fit and Finish

SPECIFICATION

ITEM

1.5646-1.5652 in. (39.741-39.756 mm)

I.D.

within 0.0002 in (0.005 mm)

Roundness

within 0.0002 in (0.005 mm)

Taper

16 RMS

Surface Finish

10. See

Figure 3-156

. Pull inner race from pinion shaft using

BEARING SEPARATOR (Part No. Snap-on Tools Stock
No. CJ950), three items from END CAP (Part No. HD-
34902-7), BRIDGE (Part No. J-7830-5) and FORCING
SCREW (Part No. J-21686-12), and two bolts. Apply heat
to race to aid removal.

11. Press new inner race on pinion shaft using shop-made

tool. When the tool bottoms against the flywheel, the cor-
rect inner race location is automatically established as
shown in

Figure 3-160

. The new inner race must be

ground by a machinist to an O.D. dimension range based
on the finished lapped I.D. of the outer race, as shown in

Table 3-39

. See the example that follows.

Table 3-42. Inner Race Fit and Finish

SPECIFICATION

ITEM

within 0.0002 in. (0.005 mm)

Roundness

within 0.0002 in. (0.005 mm)

Taper

16 RMS

Surface finish

sm03414

Pinion shaft inner race

Flywheel (gear side)

1.135-1.145 in. (28.83-29.08 mm)

Figure 3-160. Inner Race Location

Inner Bearing Finish Example

The following example illustrates how to determine the required
inner race O.D.

If smallest measured I.D. of outer race is 1.5651 in.
(39.754 mm) the

Table 3-39

indicates an inner race O.D.

range of 1.2496-1.2504 in. (31.740-31.760 mm) is
required.

NOTE

Have machinist grind outer race to center or middle of required
O.D. range. This will prevent grinding outer race undersize and
gives a more easily achieved tolerance range.

Grind inner race O.D. to the middle of the desired range
as determined by

Table 3-39

. Measure O.D. at four places

and check that specifications in

Table 3-42

are met.

For example purposes:

the largest measured O.D. of inner race after grinding
is 1.2499 in. (31.747 mm) O.D.

Refer to

Table 3-39

. With a 1.5651 in. (39.754 mm)

I.D. outer race and a 1.2499 in. (31.747 mm) O.D.
inner race, a blue bearing is required.

HOME

2009 Sportster Service: Engine 3-127

sm03435

2.00 in. (50.8 mm)

1.00 in. (25.4 mm)

1.560 in. (39.62 mm)

0.187 in. (4.75 mm)

5/16 in. drill

Figure 3-161. Pinion Shaft Outer Race Installation Tool

sm03436

1.70 in. (43.2 mm)

1.00 in. (25.4 mm)

1.560 in. (39.62 mm)

0.187 in. (4.75 mm)

5/16 in. drill

Figure 3-162. Pinion Shaft Outer Race Removal Tool

sm03437

1.50 in. (38.1 mm)

1.00 in. (25.4 mm)

5.50 in. (139.7 mm)

1.135-1.145 in. (28.83-29.08 mm)

1.262-1.272 in. (32.05-32.31 mm)

Figure 3-163. Pinion Shaft Inner Race Installation Tool

LAPPING ENGINE MAIN BEARING RACES

TOOL NAME

PART NUMBER

LAPPING TOOL ADAPTER

HD-46287

CRANKCASE MAIN BEARING LAP-
PING TOOL

HD-96710-40C

CRANKCASE MAIN BEARING LAP

HD-96718-87

See

Figure 3-164

. Obtain CRANKCASE MAIN BEARING

LAPPING TOOL (Part No. HD-96710-40C). Assemble
CRANKCASE MAIN BEARING LAP (Part No. HD-96718-
87) to lapping handle.

NOTE

Left main bearing must be installed in left crankcase in order
to use LAPPING TOOL ADAPTER (Part No. HD-46287) in the
next step. See

3.18 BOTTOM END OVERHAUL: ASSEMBLY,

Crankcase

Assemble LAPPING TOOL ADAPTER (Part No. HD-
46287) to left main bearing.

HOME

3-128 2009 Sportster Service: Engine

Secure right and left crankcase halves with three crank-
case stud bolts (top center and bottom left and right).

Insert lap shaft with arbor assembled through pinion
bearing bushing and into lapping tool adapter. Tighten
arbor expansion collars using a length of 0.156 in. (3.96
mm) rod as spanner until arbor begins to drag. Do not
adjust arbor snug in bushing or bushing will bell, a condi-
tion where hole is larger at ends than it is in the center.

Withdraw arbor far enough to coat lightly with 220 grit
lapping compound. Do not apply a heavy coat. Reposition
lap in bushing and turn handle at moderate hand speed.
Work lap back and forth in bushing, as it is revolved, to
avoid grooving and tapering.

At frequent intervals, remove lap from crankcase, wash
and inspect bushing. Lapping is completed when entire
bushing surface has a dull, satin finish rather than a glossy,
smooth appearance.

When finished, flush off lap tool using cleaning solvent
and dry using compressed air. Apply fresh, light coat of
fine lapping compound.

sm01499

Figure 3-164. Lapping Pinion Shaft Main Bearing

ASSEMBLING CRANKCASE HALVES

To assemble bottom end, see

3.18 BOTTOM END OVER-

HAUL: ASSEMBLY

HOME

2009 Sportster Service: Engine 3-129

3.24

OIL PUMP: XL MODELS

GENERAL

The oil pump seldom needs servicing. Before you disassemble
an oil pump suspected of not producing adequate oil pressure,
be sure that all possible related malfunctions have been elim-
inated.

Make sure all oil line connections are tight and that lines
are not pinched or damaged.

Check level and condition of oil in tank. Pressure will be
affected if oil is diluted. In freezing weather, proper circu-
lation of oil can be affected if the oil feed line becomes
clogged with ice or sludge.

Check for a grounded oil pressure switch wire [120] or
faulty switch if oil pressure indicator light fails to go out
with engine running.

See

3.8 ENGINE LUBRICATION SYSTEM

3.27 OIL TANK

and

6.36 OIL PRESSURE SWITCH

for additional information.