Harley Davidson Sportster Models 2009. Service Repair Manual

NOTES

TORQUE VALUE

FASTENER

4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models

6.8 Nm

60 in-lbs

TMAP sensor screw

4.8 THROTTLE POSITION (TP) SENSOR, Install-
ation: XR Models

3.3 Nm

29 in-lbs

TP sensor mounting screw (XR models)

4.8 THROTTLE POSITION (TP) SENSOR, Install-
ation: XL Models

4.0 Nm

35 in-lbs

TP sensor screw

4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XL
Models

4.0 Nm

35 in-lbs

TP sensor screw

HOME

2009 Sportster Service: Fuel System 4-3

4.2

SPECIFICATIONS: FUEL SYSTEM

SPECIFICATIONS: 2009 SPORTSTER
MODELS

Table 4-1. Capacities: 2009 Sportster 883 Models

XL 883L

LOW

XL 883C

CUSTOM

XL 883

XL 883R

ITEM

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

12.49

3.30 gal.

17.03

4.50 gal.

12.49

3.30 gal.

Fuel tank (total)

2.65

2.80 qt.

2.65

2.80 qt.

2.65

2.80 qt.

Oil tank with filter

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

Transmission (approximate)

3.03

0.80 gal.

3.79

1.00 gal.

3.03

0.80 gal.

Low fuel warning light on

Table 4-2. Capacities: 2009 Sportster 1200 Models

XR 1200

XL 1200N

NIGHTSTER

XL 1200L

LOW

XL 1200R

ROADSTER

XL 1200C

CUSTOM

ITEM

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

13.25

3.50 gal.

12.49

3.30 gal.

17.03

4.50 gal.

17.03

4.50 gal.

17.03

4.50 gal.

Fuel tank
(total)

2.65

2.80 qt.

2.65

2.80 qt.

2.65

2.80 qt.

2.65

2.80 qt.

2.65

2.80 qt.

Oil tank
with filter

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

Transmission
(approximate)

1.89

0.50 gal.

3.03

0.80 gal.

3.79

1.00 gal.

3.79

1.00 gal.

3.79

1.00 gal.

Low fuel warning
light on

HOME

4-4 2009 Sportster Service: Fuel System

4.4

AIR CLEANER: XL MODELS

REMOVAL

See

Figure 4-1

. Remove two screws (1) and trim insert

(2) from air cleaner cover (3).

Remove air cleaner cover from air cleaner backplate (10).
Remove air cleaner seal (4) from air cleaner cover.

Remove three screws (5). Remove air filter element (6)
and gasket (7) from air cleaner backplate. Discard gasket.
If filter element is being removed for cleaning only, proceed
to

4.4 AIR CLEANER: XL MODELS, Cleaning, Inspection

and Repair

which follows.

Install air filter before running engine. Failure to do so can
draw debris into the engine and could result in engine
damage. (00207a)

Remove two breather screws (9) from air cleaner back-
plate.

Remove air cleaner backplate and gasket (11). If snorkel
insert (12) needs to be repaired or replaced, remove it
from air cleaner backplate.

x0242a4x

Filter element gasket

Screw (2)

Trim insert

O-ring (2)

Breather screw (2)

Air cleaner cover

10.

Air cleaner seal

Air cleaner backplate

11.

Backplate gasket

Screw (3)

12.

Air filter element (includes item 7)

Snorkel insert

Figure 4-1. Air Cleaner Assembly

CLEANING, INSPECTION AND REPAIR

See

Figure 4-1

. Thoroughly clean air cleaner backplate

(10) and inside of air cleaner cover (3).

If air filter element (6) is damaged or if filter media cannot
be adequately cleaned, replace element and proceed to
step 6.

Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)

HOME

4-6 2009 Sportster Service: Fuel System

Wash air filter element thoroughly in warm, soapy water.
To remove soot and carbon, soak air filter element for 30
minutes in warm water with mild detergent.

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)

Dry air filter element using low-pressure compressed air.
Rotate air filter element while moving air nozzle up and
down filter element interior. Do not tap air filter element
on hard surface.

Hold air filter element up to strong light source. Element
can be considered sufficiently clean if light is uniformly
visible through filter material.

Examine o-rings (8). If damaged, replace with new o-
ring(s).

Examine air cleaner seal (4). If cracked, torn or otherwise
damaged, replace with new seal.

Repair or replace snorkel insert (12) as necessary.

NOTE

On California models, a gravity operated trap door in the air
cleaner's snorkel is closed when the engine is not running, to
seal the inlet port of the air cleaner backplate. This prevents
hydrocarbon vapors emanating from the induction module
throat from escaping into the atmosphere. When the vehicle
is running, engine vacuum holds the trap door open.

On California models, open the trap door in the snorkel
with a finger, then release. Observe the trap door to make
sure it closes smoothly and completely, without binding.

INSTALLATION

See

Figure 4-1

. If snorkel insert (12) was removed from

air cleaner backplate, slide insert into air cleaner backplate
and snap into place.

Position new gasket (11) and air cleaner backplate (10)
at induction module air inlet. Secure air cleaner backplate
to engine heads with two breather screws (9). Tighten to
120-144 in-lbs (13.6-16.3 Nm).

Apply a thin coat of engine oil or light grease to o-rings
(8). This will help prevent them from being damaged when
air filter element is installed.

Position new gasket (7) on air cleaner backplate. Make
sure gasket holes are lined up with backplate holes.

Install air filter element (6) onto backplate. Secure with
three screws (5). Tighten to 40-60 in-lbs (4.5-6.8 Nm).

Install air cleaner seal (4) on air cleaner cover (3). To
ensure proper sealing, make sure air cleaner seal covers
the entire edge of the air cleaner cover.

Install air cleaner cover onto backplate. Make sure air
cleaner seal fits inside backplate and is not pinched or
distorted.

Install trim insert (2), and secure insert and air cleaner
cover with two screws (1). Tighten to 36-60 in-lbs (4.1-
6.8 Nm).

HOME

2009 Sportster Service: Fuel System 4-7

4.5

AIRBOX: XR MODELS

REMOVAL

Remove the fuel tank. See

4.7 FUEL TANK: XR MODELS

Disconnect active intake solenoid connector located at
the rear of the airbox.

Lift airbox off induction module, trying to leave the interface
grommet attached to the induction module.

Disconnect crankcase vent hoses from the front and rear
rocker cover fittings and remove airbox assembly from
motorcycle.

Remove filter element as necessary. See

1.25 AIR

CLEANER: XR MODELS

Inspect hoses, interface grommet and housings for
deterioration, cracks, or other damage. Repair or replace
as necessary.

INSTALLATION

See

Figure 4-2

. Install any hoses that have been removed

from the airbox assembly. Ensure the anchor barb (1) of
the front crankcase vent hose is securely installed in the
hole (2) in the airbox bottom.

If removed, install air filter element and cover. See

1.25 AIR CLEANER: XR MODELS

See

Figure 4-3

. If removed, install interface grommet on

induction module. Ensure it is completely seated on the
throat (1) of the induction module.

While holding airbox in approximate installed location,
connect crankcase vent hoses to the fittings (2) on the
front and rear rocker covers. Ensure clamps are in place.

NOTE

It is extremely important that the interface grommet be correctly
and securely installed on the induction module and the airbox.
Failure to do so will result in ingestion of dirt and debris that
would otherwise be caught by the filter element, resulting in
possible decrease of engine life.

Place airbox assembly over interface grommet and work
grommet into airbox opening until securely seated. Edge
of hole in airbox will completely encircle the groove molded
in the grommet when installed correctly.

Mate active air solenoid connector.

Install fuel tank. See

4.7 FUEL TANK: XR MODELS

sm05088

Anchor barb

Anchor hole in airbox

Vent hose clamp

Figure 4-2. Front Crankcase Vent Hose

sm05090

Induction module throat

Fittings on rocker covers

Figure 4-3. Airbox Connections

HOME

4-8 2009 Sportster Service: Fuel System

4.6

FUEL TANK: XL MODELS

GENERAL

Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)

NOTE

See

Figure 4-4

. Turn the fuel filler cap (2 or 13) clockwise until

at least three clicks are heard in order to verify that it is securely
fastened to the fuel tank (1 or 12).

x0089g4x

Fuel tank (XL 883C/XL 1200C/XL 1200L)

Fuel tank filler cap (XL 883C/XL 1200C/XL 1200L)

Gasket

Screw (long)

Screw (short)

Washer (4)

Locknut (2)

Protective cap (2)

Cosmetic cover (2)

10. Ignition coil bracket
11. Console (XL 1200C)
12. Fuel tank (XL 883/XL 883L/XL 883R/XL 1200N/XL 1200R)
13. Fuel tank filler cap (XL 883/XL 883L/XL 883R/XL 1200N/XL 1200R)

Figure 4-4. Fuel Tank and Mounting Hardware

HOME

2009 Sportster Service: Fuel System 4-9

PURGING AND DISCONNECTING FUEL
SUPPLY HOSE

When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)

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 line of high pressure gasoline.

Open left side cover. See

2.20 LEFT SIDE COVER

See

Figure 4-5

. Remove fuel pump fuse (1) located

in fuse panel in front of battery.

Start engine and allow vehicle to run.

When engine stalls, operate starter for 3 seconds to
remove any remaining fuel from fuel hose.

Shut off ignition and reinstall fuel pump fuse.

Do not thread hex nut onto valve more than two turns to
prevent "bottoming" nut on valve, which can cause a fuel
leak. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00276a)

See

Figure 4-6

. Push up on release sleeve (1) on fuel

pump quick-connect fitting and pull down on fuel supply
hose fitting (2) to disconnect fuel supply hose (3) from fuel
pump module (4). Immediately clean up any fuel spills.

12411

Fuel pump fuse

Fuel pump connector [141]

Figure 4-5. Fuel Pump Fuse and Connector

12686

Release sleeve (quick-connect fitting)

Fuel supply hose fitting

Fuel supply hose

Fuel pump module

Figure 4-6. Fuel Tank Quick-Connect Fitting

REMOVING FUEL TANK

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

Remove main fuse. See

6.38 MAIN FUSE

Remove seat.

NOTE

If the fuel tank is being removed only to gain access to items
otherwise hidden, it is not necessary to drain the fuel from the
tank. If the fuel tank is to be disassembled or repaired, follow
the step below to drain the fuel.

Drain fuel tank:

Obtain a suitable fuel transfer pump with a long, flex-
ible nozzle.

Position vehicle upright. Remove fuel tank filler cap.

Insert fuel transfer pump nozzle into fuel tank filler
spout. Aim nozzle toward right side of fuel tank to
avoid contacting and damaging fuel pump assembly.

Direct the pump output into a suitable container.

Pump fuel until fuel tank is empty.

Immediately wipe up any spilled fuel.

See

Figure 4-7

. Remove vent hose from fuel tank vent

nipple. Remove cable clip (3) securing fuel pump wiring
harness (2) to mounting boss on H-bracket.

See

Figure 4-5

. Unplug fuel pump connector (2) [141].

See

Figure 4-4

. Remove protective caps (8), lock nuts (7),

screws (4, 5) and washers (6) from front and rear of fuel
tank.

Place a clean, soft cloth over front of fuel tank to keep tank
from contacting top fork clamp and damaging paint. Lift

HOME

4-10 2009 Sportster Service: Fuel System

up rear of fuel tank. Remove fuel pump harness from clip
on wire harness caddy latch clip on frame backbone.

Lift fuel tank off motorcycle.

Remove fuel pump assembly. See

4.18 FUEL PUMP

sm01547

Fuel tank vent hose

Fuel pump wiring harness

Cable clip

Figure 4-7. Fuel Tank Vent Hose

CLEANING AND INSPECTION

Extreme caution should be taken when repairing fuel tanks.
Make sure all traces of fuel are purged before making an open
flame repair.

Clean fuel tank interior with commercial cleaning solvent
or a soap and water solution. Shake fuel tank to agitate
cleaning agent.

Thoroughly flush fuel tank after cleaning. Allow fuel tank
to air dry.

Carefully inspect fuel hose and vent hose for damage,
cuts, cracks, holes, wear or general deterioration. Replace
as necessary.

Inspect the fuel tank for leaks or other damage. If a dam-
aged fuel tank cannot be successfully repaired, replace
it.

INSTALLING FUEL TANK

NOTE

Be sure wiring harnesses do not get pinched between fuel tank
and frame during tank installation.

Install fuel pump into fuel tank using new gasket. See

4.18 FUEL PUMP

See

Figure 4-8

. Position fuel tank on motorcycle. Make

certain that front fuel tank brackets are located outboard
of ignition coil bracket (8).

Place washer (4) on long screw (2). Push screw through
front fuel tank bracket, ignition coil bracket and frame, from
right to left. Place second washer over screw and hand-
start lock nut (5).

x0671a4x

Fuel tank (typical)

Screw (long)

Screw (short)

Washer (4)

Lock nut (2)

Protective cap (2)

Cosmetic cover (2)

Ignition coil bracket

Figure 4-8. Fuel Tank Mounting (Typical)

See

Figure 4-9

. Place a clean, soft cloth over front of fuel

tank to keep tank from contacting top fork clamp and
damaging paint. Lift up rear of fuel tank. Place fuel pump
wiring harness (1) into clip on wire harness caddy latch
clip on frame backbone tube. Make sure harness forms a
loop (5) between caddy latch clip and fuel pump module
(6) to avoid pinching harness between fuel tank and frame
backbone tube.

Route fuel pump wiring harness down along left side of
H-bracket. Secure with cable clip (3). Push clip into hole
in mounting boss (2) on H-bracket.

See

Figure 4-5

. Plug in fuel pump connector (2) [141].

Lower rear of fuel tank into position. See

Figure 4-8

. Place

washer (4) on short screw (3). Push screw through rear
fuel tank bracket and frame, from right to left. Place second
washer over screw and hand-start lock nut (5).

Tighten both front and rear fuel tank mounting screws to
15-20 ft-lbs (20.4-27.1 Nm). Install protective caps (6) on
screw ends.

See

Figure 4-7

. Install vent hose onto fuel tank vent nipple.

HOME

2009 Sportster Service: Fuel System 4-11

sm01549

Fuel pump wiring harness

Cable clip mounting boss on H-bracket

Cable clip

Wire harness caddy latch clip

Fuel pump wiring harness loop

Fuel pump module

Figure 4-9. Fuel Pump Wiring Harness Routing

RECONNECTING FUEL HOSE AND FILLING
FUEL TANK

To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)

See

Figure 4-6

. Push up on release sleeve (1) and push

fuel hose fitting (2) into fuel pump module fuel pump quick-
connect fitting. Pull down on release sleeve to lock quick-
connect fitting. Tug on fuel hose fitting to make sure it is
securely locked in place.

See

Figure 4-7

. Install vent hose onto vent nipple on fuel

tank.

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Fill fuel tank and carefully inspect for leaks around fuel
pump module.

Install main fuse. See

6.38 MAIN FUSE

Turn ignition switch ON and verify fuel pump is activated.
Carefully inspect for leaks at quick-connect fitting. Turn
ignition switch OFF.

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)

Install seat.

VAPOR VALVE

Excessive pressure can build in the fuel tank if vapor valve
is not mounted vertically with long fitting to top. Leaks
due to excessive pressure can cause a fire or explosion,
which could result in death or serious injury. (00265a)

See

Figure 4-10

. The fuel tank (1) is vented through a stand-

pipe (vent tube) within the tank. A hose (2) at the base of the
fuel tank is connected to the standpipe.

Keep vent and vapor valve lines away from exhaust and
engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00263a)

See

Figure 4-11

. The fuel tank vent hose (2) is connected to

a vapor valve (4) located beneath the seat in front of the battery
tray. On non-California models, another hose (5) vents the
vapor valve to the atmosphere. On California models, that hose
is routed to the charcoal canister. See

4.21 EVAPORATIVE

EMISSIONS CONTROL (CA MODELS)

NOTES

•

See

Figure 4-12

. Mount the vapor valve (1) in an upright

position with the longer fitting positioned at the top or
excessive fuel vapor pressure may build up within the fuel
tank.

•

See

Figure 4-12

. Do NOT force vapor valve (1) into clip

(2). Forcing valve in to clip could cause clip to break,
necessitating replacement of entire wiring harness guide
(4).

HOME

4-12 2009 Sportster Service: Fuel System

12387

Fuel tank

Fuel tank-to-vapor valve hose

Figure 4-10. Fuel Tank Venting System

12327

Battery

Fuel tank-to-vapor valve hose

Vapor valve clip (on wiring harness guide)

Vapor valve

Vapor-valve-to-atmosphere hose (non-California
models)

Figure 4-11. Vapor Valve Assembly

12328

Vapor valve

Vapor valve clip

Fuel tank-to-vapor valve hose

Wiring harness guide

Figure 4-12. Vapor Valve Mounting

CONSOLE REPLACEMENT

TOOL NAME

PART NUMBER

CONSOLE ALIGNMENT RING

HD-47114

In addition to the CONSOLE ALIGNMENT RING (Part No. HD-
47114), other special tools are needed:

•

Temporary use of a smaller diameter fuel filler cap (H-D
Part Number 61272-92B). This is the original equipment
cap found on 2004 or later XL 883, XL 883L, XL 883R and
XL 1200R models, as well as many other Harley-Davidson
models.

•

Approximately 18 in. (460 mm) fishing line (or string) to
aid in removing the existing console.

Removal

Remove seat.

See

Figure 4-13

. Remove the original fuel filler cap (2)

from the fuel tank (1) and set it aside. Obtain a small dia-
meter Harley-Davidson fuel filler cap (5) and screw it into
the fuel filler opening.

See

Figure 4-14

. Insert the fishing line (2) between the

rear of the fuel tank and the plastic liner (1) on the under-
side of the original console.

HOME

2009 Sportster Service: Fuel System 4-13

NOTE

Raise the ends of the fishing line away from the fuel tank to
avoid scuffing the tank finish.

Using a side-to-side "sawing" motion, work the fishing line
toward the front of the fuel tank to break the adhesive bond
between the console and the tank.

Carefully remove the console and liner from the fuel tank
and discard it.

NOTES

•

Be careful not to scratch the paint on the fuel tank when
removing the adhesive.

•

To avoid damaging the fuel tank finish, do not use tools
or abrasive cleaners to remove the adhesive residue that
remains on the fuel tank surface. Try to stay within the
area that will be covered by the new console.

See

Figure 4-15

. To remove any adhesive residue

remaining on the fuel tank surface:

Carefully peel off as much adhesive as possible, using
your thumb and fingers only.

NOTE

Use of cleaning compounds other than isopropyl alcohol
may damage fuel tank finish. Test in inconspicuous area.

Clean the top of the fuel tank with a mixture of 50%
to 70% isopropyl alcohol and 30% to 50% distilled
water or, if necessary, straight isopropyl alcohol.

Allow the fuel tank surface to dry thoroughly.

x0634x7x

Fuel tank

Original equipment fuel filler cap

Fuel tank console

Console alignment ring (Part No. HD-47114)

Small-diameter fuel filler cap

Figure 4-13. Replacing Console: XL 1200C

12281

Original fuel tank console liner

Fishing line or string

Figure 4-14. Removing Existing Console

10751

Figure 4-15. Removing Adhesive Residue

Installation

See

Figure 4-16

. Measure and mark the centerline of the

fuel tank at the rear of the tank.

Obtain the new fuel tank console. Measure and mark the
centerline of the console at the rear of the panel.

See

Figure 4-17

. Place CONSOLE ALIGNMENT

RING (Part No. HD-47114) over the fuel filler cap.

Peel the liner from the adhesive backing of the console.

See

Figure 4-18

. Position the console over the fuel tank

without touching the adhesive to the tank surface. Center
the large hole over the CONSOLE ALIGNMENT
RING (Part No. HD-47114) tool, and align the mark on the
rear of the console with the mark made on the rear of the
fuel tank.

Slide the front of the console down over the CONSOLE
ALIGNMENT RING (Part No. HD-47114) tool onto the fuel
tank. Bring the rear of the console down, keeping the
marks aligned.

Press the console firmly against the top of the fuel tank
and hold pressure for 30 seconds. After releasing pres-

HOME

4-14 2009 Sportster Service: Fuel System

sure, avoid direct contact with the console for about 20
minutes, then remove the CONSOLE ALIGNMENT
RING (Part No. HD-47114) tool.

Remove the small-diameter fuel filler cap and install the
original fuel filler cap.

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)

Install seat.

10. Allow AT LEAST 24 hours after applying the console

before exposing the area to vigorous washing, strong water
spray or extreme weather. The adhesive bond will increase
to maximum strength after about 72 hours at normal room
temperatures.

10752

Figure 4-16. Marking Fuel Tank Centerline

10753

Figure 4-17. Placing Console Alignment Ring Tool (Part

No. HD-47114)

10764

Figure 4-18. Positioning Console on Fuel Tank

HOME

2009 Sportster Service: Fuel System 4-15

4.7

FUEL TANK: XR MODELS

GENERAL

PURGING AND DISCONNECTING FUEL
SUPPLY HOSE

Purge the fuel supply line of high pressure gasoline.

Open left side cover. See

2.20 LEFT SIDE COVER

See

Figure 4-19

. Remove fuel pump fuse (1) located

in fuse panel in front of battery.

Start engine and allow vehicle to run.

When engine stalls, operate starter for 3 seconds to
remove any remaining fuel from fuel hose.

Shut off ignition and reinstall fuel pump fuse.

sm04945

Fuel pump fuse

Fuel pump connector [141]

Figure 4-19. Fuel Pump Fuse and Connector

Gasoline can drain from quick-connect fitting when
removing fuel line. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. Wipe up spilled fuel immediately and dispose of
rags in a suitable manner. (00267a)

See

Figure 4-20

. Push up on release sleeve (1) on fuel

pump quick-connect fitting and pull down on fuel supply
hose fitting (2) to disconnect fuel supply hose (3). Immedi-
ately clean up any fuel spills.

sm05409

Release sleeve (quick-connect fitting)

Fuel supply hose fitting

Fuel supply hose

Throttle cable retainer

Figure 4-20. Fuel Tank Quick-Connect Fitting

REMOVING FUEL TANK

Purge the fuel supply line of high pressure gasoline. Dis-
connect fuel line from fuel tank. See

4.7 FUEL TANK: XR

MODELS, Purging and Disconnecting Fuel Supply Hose

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

Remove main fuse. See

6.38 MAIN FUSE

NOTE

HOME

4-16 2009 Sportster Service: Fuel System

Drain fuel tank:

Obtain a suitable fuel transfer pump with a long, flex-
ible nozzle.

Position vehicle upright. Remove fuel tank filler cap.

Insert fuel transfer pump nozzle into fuel tank filler
spout. Aim nozzle toward right side of fuel tank to
avoid contacting and damaging fuel pump assembly.

Direct the pump output into a suitable container.

Pump fuel until fuel tank is empty.

Replace fuel tank filler cap.

Immediately wipe up any spilled fuel.

See

Figure 4-20

. Remove retainer (4) securing throttle

cables to plate on bottom of fuel tank.

NOTE

See

Figure 4-21

. Short screws (2) secure trim ring to fuel tank

cover only. It is not necessary to remove these screws unless
either trim ring or fuel tank cover is being replaced.

See

Figure 4-21

. Remove four long screws (1) that secure

trim ring (4) and fuel tank cover (5) to fuel tank.

Carefully lift fuel tank cover off fuel tank. Slide cover for-
ward slightly as it is lifted to clear sides of fuel tank.

See

Figure 4-22

. Remove vent hose (3) from fuel tank

vent fitting (4). With a gentle twisting motion, pull ground
wire connector [210] (5) straight up off pin on fuel tank
retaining ring (6).

Remove vent hose and ground wire from trough in center
of fuel tank. Pull vent hose and ground wire back out of
the way.

See

Figure 4-19

. Unplug fuel pump connector [141] (2).

sm04947

Screw, long (4)

Screw, short (4)

Fuel cap

Trim ring

Fuel tank cover

Figure 4-21. Fuel Cap and Trim Ring

sm04948

Fuel tank

Fuel cap

Vent hose

Vent fitting

Ground wire connector [210]

Retaining ring

Figure 4-22. Fuel Tank Vent Hose and Ground Wire

10. See

Figure 4-23

. Remove two screws and washers (3)

securing airbox to bottom of fuel tank.

11. Remove screw with washer (4) from rear of fuel tank.

Remove protective plastic cap (not shown) from threaded
end of screw (6). Remove screw, washers and lock nut.

HOME

2009 Sportster Service: Fuel System 4-17

sm04952

Fuel tank

Airbox

Screw w/washer (2)

Screw w/washer

Rubber grommet

Screw w/washers and lock nut

Figure 4-23. Fuel Tank and Airbox Mounting Fasteners

12. Lift fuel tank off motorcycle.

NOTE

See

Figure 4-26

. Metal bushings (4) inside the grommets (3)

may fall when fuel tank is lifted off vehicle. Make sure they do
not fall out and become lost.

13. Remove fuel pump assembly from fuel tank. See

4.18 FUEL PUMP

DISASSEMBLE FUEL TANK

See

Figure 4-24

. Remove filler cap (1) with o-ring (2).

Remove screws (7) and clamp ring (3).

Remove top ring (4).

Remove o-ring (5).

sm05448

Filler cap

O-ring

Clamp ring

Top ring

O-ring

Fuel tank

Screw (6)

Figure 4-24. Fuel Tank Assembly

CLEANING AND INSPECTION

Extreme caution should be taken when repairing fuel tanks.
Make sure all traces of fuel are purged before making an open
flame repair.

Clean fuel tank interior with commercial cleaning solvent
or a soap and water solution. Shake fuel tank to agitate
cleaning agent.

Thoroughly flush fuel tank after cleaning. Allow fuel tank
to air dry.

Carefully inspect fuel hose and vent hose for damage,
cuts, cracks, holes, wear or general deterioration. Replace
as necessary.

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4-18 2009 Sportster Service: Fuel System

Harley Davidson Sportster Models 2009. Service Repair Manual - page 31