Harley Davidson Sportster Models 2009. Service Repair Manual - page 34

. Remove forward muffler mount fastener

(3) and washer-nut (8).

Remove two bolts (23) fastening mufflers together.

Slide upper muffler (21) back off header pipe to remove.

Remove rear muffler mount fastener (1).

4-52 2009 Sportster Service: Fuel System

Rotate lower muffler (20) counterclockwise to disengage
from the rear mount (22) and slide back off header pipe
to remove.

Remove mount grommets (5) and sleeve (9).

Inspect rear mount (22) and replace if damaged.

Inspect muffler seals (19) and replace if necessary:

Pull seal out of muffler using a hook-type tool.

Push new seal into place being careful not to distort
or damage the new seal.

Header Pipes

Remove mufflers.

Disconnect O2 sensor connectors. Remove sensor if
necessary. See

4.14 OXYGEN SENSOR

. Loosen or remove head pipe heat shields

to gain access to header pipe flange nuts (12).

Remove flange nuts (12) and pull flanges (15) off from
studs.

Remove nut (17) and carriage bolt (16) from lower clamp
(18).

NOTE

Be careful not to drop or hit header pipe assembly. Damage
to the catalytic converter may result.

Remove header pipe assembly from vehicle.

Inspect exhaust port gasket (14) and replace if necessary.

Pry gasket from exhaust port in cylinder head being
careful not to damage the bore.

Push new gasket into place with the larger ID facing
the header pipe, as shown in the inset in

Remove retainer rings (13) and flanges (15) if necessary.

If necessary, remove mount brackets (7, 22) and intercon-
nect bracket (11).

INSTALLATION

Header Pipes

See

. If removed, install flanges (15) and

retaining rings (13).

If removed, install rear mount (22), front mount (7), and
interconnect bracket (11).

Tighten fasteners (2) to 15-20 ft-lbs (20.3-27.1 Nm).

Tighten fasteners (6) to 45-50 ft-lbs (61.0-67.8 Nm).

Tighten fasteners (10) to 30-33 ft-lbs (40.7-44.7 Nm).

NOTE

Use care not to damage exhaust port gaskets (14) when posi-
tioning header pipes in exhaust port area.

Place head pipe assembly in position and loosely secure
lower clamp (18) with carriage bolt (16) and flange nut
(17).

Install flanges (15) and secure with nuts (12) finger tight.
do not tighten until mufflers are installed.

Install mufflers.

Mufflers

Place lower muffler (20) on header pipe. Rotate until rear
mount fastener (1) can be installed. Loosely install fastener
(1).

Place upper muffler (21) on header pipe.

Install muffler-to-mufffler bolts (23) finger tight.

Install grommets (5), sleeve (9), fastener (3), washer (4)
and washer nut (8). Tighten to 120-180 in-lbs (16.9-20.3
Nm).

Tighten muffler-to-muffler bolts (23) to 120-180 in-lbs
(16.9-20.3 Nm).

Tighten rear mount fastener (1) to 120-180 in-lbs (16.9-
20.3 Nm).

Be sure header pipes are clear of idler pully and tighten
nut (17) to 30-33 ft-lbs (40.7-44.7 Nm).

Tighten the exhaust flange nuts (12) to 96-120 in-lbs
(10.8-13.6 Nm).

Install heat shields.

10. Install and connect the O2 sensors. See

4.14 OXYGEN

SENSOR

2009 Sportster Service: Fuel System 4-53

4.17

FUEL INJECTORS

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)

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the fuel injectors.

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

4.7 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

XL Models with side-mounted horn: See

Figure 4-73

Remove screws (3), washers (2) and cylinder head bracket
(1) from engine. Unplug harness connectors [122] from
horn (4).

XL Models with 4.5 gallon (17.0 liter) fuel tank: Access
to the fuel injectors and fuel rail may be easier if the fuel
tank is raised up as follows:

Remove seat.

Loosen (but do not remove) front fuel tank mounting
screw. Remove rear fuel tank mounting screw,
washers and nut. See

Place a clean shop cloth between front of fuel tank
and front fork upper bracket to protect fuel tank finish.
Carefully pivot rear of fuel tank upward and prop in
position with a block of soft wood or other suitable
device.

. Unplug engine sub-harness connectors

from fuel injector connectors [84A], [85A] (7, 8).

Remove screw (5) and retaining bracket (2).

NOTE

See

Figure 4-76

. If the fuel supply hose (1) or fuel rail (6) are

not to be replaced, it is not necessary to separate them. Skip
the next step.

Disassemble fuel supply hose (1) from fuel rail (6) as fol-
lows:

Hold fuel rail in place and with a gentle twisting
motion, pull fuel supply hose straight up out of fuel
rail.

Hold fuel injectors (9, 10) in place by pressing down on
harness connectors (7, 8) and with a gentle rocking motion,
pull fuel rail off injectors.

With a gentle twisting motion, pull fuel injectors out of
intake manifold (XL models) or induction module (XR
models).

10. Remove and discard O-rings (11).

sm03401

Cylinder head bracket

Washer (2)

Screw (2)

Horn assembly

Figure 4-73. Horn and Cylinder Head Bracket (XL Models

With Side Mounted Horn Only)

4-54 2009 Sportster Service: Fuel System

sm03450

Fuel supply hose

Retaining bracket

Fuel rail

Front fuel injector and connector

Rear fuel injector and connector

Figure 4-74. Fuel Injector Assembly Location: XL Models

sm04956

Fuel supply hose

Retaining bracket

Fuel rail (not visible)

Front fuel injector and connector

Rear fuel injector and connector

Figure 4-75. Fuel Injector Assembly Location: XR Models

sm03402

Fuel supply hose

Retaining bracket

Sealing washer (only available with fuel supply
hose)

O-ring (only available with fuel supply hose)

Screw

Fuel rail

Front injector connector [84A]

Rear injector connector [85A]

Front fuel injector

10. Rear fuel injector
11. O-ring (4) (provided in repair kit)
12. Intake manifold

Figure 4-76. Fuel Injector Assemblies (typical: XL model

shown)

INSTALLATION

. Apply a thin coat of clean engine oil to

new fuel injector O-rings (11). Install O-rings onto fuel
injectors (9, 10).

Push fuel injectors into intake manifold (XL models) or
induction module (XR models) with harness connectors
(7, 8) facing up. Rotate fuel injectors so that harness
connectors are positioned, as shown in either

Figure 4-74

Figure 4-75

depending on model being serviced.

Gently press fuel rail onto free end of fuel injectors. Press
fuel rail down until hole in fuel rail molded-in bracket lines
up with mounting hole in intake manifold (12).

NOTE

An alternate method of assembly is to first install rear fuel
injector in the intake manifold (XL models) or induction module
(XR models) and front fuel injector in the fuel rail. Then install

2009 Sportster Service: Fuel System 4-55

the assembly onto the intake manifold (XL models) or induction
module (XR models).

If the fuel supply hose and fuel rail were separated in the
disassembly procedure, reassemble as follows:

See

. Inspect sealing washer (3) and O-

ring (4) for damage. If either require replacement,
install a new fuel line kit.

Lightly coat O-ring with clean engine oil. Push fuel
supply hose into fuel rail bore until collar on hose is
flush with top of fuel rail.

NOTE

The fuel supply hose must be oriented properly when installing
the retaining bracket. See

Figure 4-77

See

. Install retaining bracket (2) and fastener

(5) as follows:

Figure 4-77

. Orient fuel supply hose so that loc-

ating flange (2) is positioned as shown.

Install retaining bracket (3) so that U-shaped opening
in bracket fits around fuel supply hose and locating
flange as shown.

. Secure retaining bracket (2) with

screw (5). Tighten to 60 in-lbs (6.8 Nm).

NOTE

XR Models: See

Figure 4-75

. The fuel injector harness leads

must NEVER be routed between the retaining bracket (2) and
induction module body. Improper routing will result in chafing
of the insulation resulting in poor engine performance.

Connect engine sub-harness connectors to the fuel
injectors. Ensure wire harnesses are routed outside the
wings of retaining bracket (2) on XR models.

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)

XL Models with 4.5 gallon (17.0 liter) fuel tank: if the
fuel tank was raised up to gain access to the fuel injectors,
install fuel tank and seat:

Remove prop from under rear of fuel tank. Lower rear
of fuel tank into position and install screw, washer
and nut in fuel tank rear mounting holes. Tighten front
and rear mounting screws to 15-20 ft-lbs (20.4-27.1
Nm). Install protective caps on screw ends. See

Install seat.

Connect fuel hose to fuel pump module. Fill fuel tank and
carefully check for leaks around fuel pump module. See

XL Models with side-mounted horn: See

Figure 4-73

Plug harness connectors [122] into horn (4). Mount cylinder
head bracket (1) on engine. Secure with washers (2) and
screws (3). Tighten to 17-24 ft-lbs (23.1-32.6 Nm).

10. Install main fuse and close left side cover. See

6.38 MAIN

FUSE

sm01614

Fuel supply hose

Locating flange

Retaining bracket

Fuel rail

Figure 4-77. Mounting Fuel Hose and Fuel Rail (Typical:

XL Model Shown)

4-56 2009 Sportster Service: Fuel System

4.18

FUEL PUMP

GENERAL

Do not replace the special Teflon coated fuel pump wiring
with ordinary bulk wire. Ordinary insulation materials can
deteriorate when put in contact with gasoline and cause
an explosion, which could result in death or serious injury.
(00566b)

NOTE

Carefully inspect fuel hose for cuts, tears, holes or other
damage. Replace hose if any damage is found. Even a small
hole can cause a reduction in fuel pressure.

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the fuel pump.

REMOVAL

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

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

Figure 4-78

. Unplug fuel pump harness connector

[141] (1), located forward of fuse/relay block on left side
of vehicle.

XL Models: Remove seat.

Drain and remove fuel tank from vehicle. See

4.6 FUEL

TANK: XL MODELS

4.7 FUEL TANK: XR MODELS

Figure 4-79

. Lay fuel tank upside-down on a soft cloth.

Remove five screws (3).

Carefully lift fuel pump module out of fuel tank. See

Figure 4-80

. To facilitate removal, tilt module when it is

almost completely free of fuel tank.

Figure 4-78

. Remove and discard cover plate seal

(7).

12621

Fuel pump harness connector [141]

Fuel pump

Fuel filter housing

Sending unit float

Quick-connect fitting

Cover plate

Cover plate seal

Figure 4-78. Fuel Pump Module

2009 Sportster Service: Fuel System 4-57

12323

Fuel tank

Fuel pump module

Screw (5)

Fuel pump harness

Quick-connect fitting

Figure 4-79. Fuel Pump Module: All Models (XL Shown)

12324

Figure 4-80. Removing/Installing Fuel Pump Module: All

Models (XL Shown)

DISASSEMBLY

The disassembly procedure is broken down into the following
groups:

•

Pressure regulator and filter housing.

•

Fuel pump assembly and pump bracket.

•

Low fuel level sensor assembly.

•

Fuel pump/sender harness.

12621

Cable strap (3)

Pump assembly clamp

Pump bracket

Filter housing hose

Figure 4-81. Fuel Pump Assembly: Location of Cable

Straps and Pump Clamp

NOTE

See

Figure 4-81

. When disassembling or assembling the fuel

pump and sender assembly, refer to this figure for the relative
positions of the wiring harness cable straps (1) and pump
assembly clamp (2).

Pressure Regulator and Filter Housing

Figure 4-81

. Cut and discard cable strap (1) securing

wiring harness to the filter housing hose (4).

See

Figure 4-82

. Remove ground clip (12) from top of filter

housing (23).

Remove and discard clamp (1). Remove filter housing
hose from top of fuel pump (2).

Remove retaining clip (24) from top of filter housing and
remove pressure regulator (22).

Remove second retaining clip (24) from bottom of filter
housing and remove filter housing. Remove fuel filter ele-
ment (25) from housing.

4-58 2009 Sportster Service: Fuel System

As required, remove negative (-) battery cable from battery.

Figure 6-29

. As required, pull back rubber cap (3) and

using a 12 mm wrench, remove nut with captive lock
washer (5) and positive (+) battery cable (2) from starter
post (4).

sm01168

Starter assembly

Positive (+) battery cable

Rubber cap

Starter post

Nut with captive lock washer

Figure 6-29. Positive (+) Cable Starter Post Connection:

All Models (XL Shown, Right Side View - Rubber Cap Pulled

Back)

INSTALLATION

Route fastener through negative (-) battery cable ring and
into negative (-) battery terminal of a fully charged battery.
Position negative (-) battery cable so that it hangs straight
down from negative (-) battery terminal. Tighten to 60-70
in-lbs (6.8-7.9 Nm).

Apply a light coat of petroleum jelly or corrosion retardant
material to the negative (-) battery terminal.

Figure 6-28

. Slide battery in battery tray. Route neg-

ative (-) battery cable (1) around frame downtube.

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)

Figure 6-27

. With negative (-) battery cable discon-

nected from ground on crankcase, thread fastener through

main fuse cable first, then through positive (+) battery
cable, and into positive (+) battery terminal (2). Tighten to
60-70 in-lbs (6.8-7.9 Nm).

Apply a light coat of petroleum jelly or corrosion retardant
material to the positive (+) battery terminal. Place pro-
tective rubber boot over terminal.

Hook top of battery strap (3) to battery tray mount on top
of battery. Install screw (6) and tighten to 36-60 in-lbs
(4.1-6.8 Nm).

Snap positive (+) battery cable into holders on electrical
bracket.

Hook main fuse cover (4) to pin on battery strap and slide
forward until it snaps into place.

Hook data link connector [91A] (5) to pin on battery strap
and slide forward until it snaps into place.

10. See

Figure 6-29

. Install positive (+) battery cable (2) and

nut with captive lock washer (5) on starter post (4). Using
a 12 mm wrench, tighten lock nut to 60-85 in-lbs (6.8-9.6
Nm).

11. Push rubber cap (3) over starter post.

12. See

Figure 6-28

. Press negative battery cable (1) into

cable clip (4).

13. Place negative battery cable connector onto stud on

crankcase boss behind starter motor assembly (3). Thread
nut (2) onto crankcase ground stud behind starter motor.

14. See

Figure 6-30

. Press negative battery cable connector

against cable stop on crankcase and tighten nut to 55-75
in-lbs (6.2-8.5 Nm).

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)

15. Install seat.

sm01169

Figure 6-30. Negative Battery Cable Stop on Crankcase

2009 Sportster Service: Electrical 6-25

6.12

BATTERY TRAY

GENERAL

. The battery tray is located behind the vehicle's

left side cover. The battery tray is a light-weight, sturdy plastic
assembly which supports the battery, TSM/TSSM/HFSM, and
rear brake lamp switch assembly (XL models only).

REMOVAL

Remove left side cover. See

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 battery cables, negative cable first, and remove
battery. See

SECURITY MODULE (TSM/TSSM/HFSM)

Reach under battery tray and push TSM/TSSM/HFSM up
from cavity in bottom of tray. Unplug and remove
TSM/TSSM/HFSM. See

6.10 TURN SIGNAL AND

XL models only: see

2.15 REAR BRAKE MASTER CYLINDER

. Reposition rear brake

lamp switch as follows:

Remove rear brake master cylinder reservoir cover
by grasping cover and gently pull straight out from
reservoir. Unbolt reservoir and secure out of the way
with an elastic tiedown cord, mechanic's wire or cable
strap. See

RESERVOIR

Remove screw securing rear brake hose clamp (1)
to battery tray (2).

Remove TORX screw (3) securing rear brake lamp
switch assembly (4) to battery tray. Gently pull brake
lamp switch assembly back out of the way. Do not
bend or stress metal brake lines.

sm00906

Rear brake hose clamp

Battery tray

TORX screw

Rear brake lamp switch assembly

H-bracket

TSM/TSSM/HFSM 12-pin connector [30B]

4-pin connector [208B] (HFSM only)

Figure 6-31. Battery Tray Assembly

See

Figure 6-32

. Remove three screws (4) securing bat-

tery tray to mounting tabs (5) on frame.

Figure 6-33

. Slide H-bracket (1) up frame tube as far

as possible and disengage battery tray upright support (3)
from tabs (2) on H-bracket.

Lift up battery tray slightly so that mounting tabs will clear
mounts on frame. See

Figure 6-32

. As you lift up on tray,

pull down gently on end of battery strap support (3) to
clear frame and wiring harnesses above battery tray.

Slide battery tray out and remove from left side of vehicle.

6-26 2009 Sportster Service: Electrical

sm01344

Frame

Battery tray

Battery strap support

Screw (3)

Tray mounting tabs on frame (3)

Figure 6-32. Battery Tray Mounting Screws

sm00915

H-bracket

Tabs

Upright support

Battery tray

Figure 6-33. Battery Tray H-Bracket Support

INSTALLATION

. Make sure connector [30B] (6), connector

[208B] (7) (HFSM only) and rear brake lamp switch
assembly (4) are out of the way.

Slide battery tray (2) into place behind H-bracket (5). Make
sure battery tray mounting tabs are positioned behind (to
the right of) frame mounts.

Figure 6-33

. Push H-bracket (1) up as far as possible

and engage battery tray upright support (3) into tabs (2)
on H-bracket.

See

Figure 6-32

. Install three screws (4) to secure battery

tray to frame. Do not tighten screws until all three have
been started. Then tighten screws to 96-156 in-lbs (10.9-
17.6 Nm).

XL models only: see

2.15 REAR BRAKE MASTER CYLINDER RESER-
VOIR

. Position rear brake

lamp switch as follows:

Install rear brake lamp switch (4). Secure with TORX
screw (3). Tighten to 72-120 in-lbs (8.1-13.6 Nm).

Secure brake hose clamp (1) to battery tray with
screw. Tighten to 30-40 in-lbs (3.4-4.5 Nm).

Install rear brake master cylinder reservoir. Secure
using screw with captive washer. Tighten to 20-25 in-
lbs (2.3-2.8 Nm). Install reservoir cover. See

6.10 TURN SIGNAL AND SECURITY MODULE

2009 Sportster Service: Electrical 6-27

Plug connector [30B] into TSM/TSSM/HFSM. If equipped,
plug connector [208B] into HFSM. Install
TSM/TSSM/HFSM into cavity in bottom of battery tray.
See

(TSM/TSSM/HFSM)

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

Install left side cover. See

6-28 2009 Sportster Service: Electrical

6.13

STARTER

GENERAL

The starter is made up of a field coil assembly, solenoid
assembly and drive assembly. The repair instructions contained
in this section are divided into three major service areas
accordingly.

NOTE

For troubleshooting and diagnostic information, see the
ELECTRICAL DIAGNOSTIC MANUAL for this motorcycle.

Wiring Diagrams

The starting circuit wiring diagram contains information about
wiring configuration. For additional information, see the
ELECTRICAL DIAGNOSTIC MANUAL for this motorcycle.

Paint Touch-Up

On painted starters, paint is applied to the starter after
assembly. Many of the procedures in this section involve dis-
assembly of several painted joints. When servicing the starter,
paint damage or flaking may occur in the area of these joints.
Any damaged paint should be touched up after assembly prior
to installation using the appropriate touch up paint. Follow the
directions provided with the paint. Paint flaking does not require
the starter to be replaced.

REMOVAL

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)

Remove negative (-) battery cable from stud on engine
crankcase boss behind starter motor assembly. See

Open left side cover. See

Remove positive (+) battery cable from battery positive
(+) terminal. See

5.3 PRIMARY CHAIN ADJUSTER

Close left side cover.

Drain transmission lubricant and remove primary cover.
See

Remove rear muffler and exhaust pipe. See

4.15 EXHAUST SYSTEM: XL MODELS

4.16 EXHAUST

SYSTEM: XR MODELS

Remove positive (+) battery lead and solenoid wire from
starter.

NOTE

A ball hex driver may be required to gain access to the starter
mounting bolts.

See

Figure 6-34

. Remove the two starter mounting bolts

and washers.

Remove starter and gasket from right side of motorcycle.

11501

Figure 6-34. Starter Mounting Bolts

FIELD COIL ASSEMBLY

Disassembly

Remove allen head screw to release chrome end cover,
if equipped.

Remove two Keps nuts to release end cover bracket from
thru bolts, if equipped.

Pull up rubber boot and remove hex nut with captive
lockwasher to release field wire ring terminal from post on
solenoid housing.

Using a 5/16 inch socket, loosen two thru bolts to release
field coil from solenoid housing.

Pull field coil with end cap from solenoid housing.

Remove armature from field coil. Separating end cap and
field coil flanges will facilitate removal.

Placing field coil on wooden block to prevent damage, use
impact driver to remove two Phillips screws with captive
washers from end cap. Discard screws.

Remove end cap from field coil.

Locate the two brushes attached to the field coil winding.
Pushing on inboard side of one brush, grasp free end of
brush spring on outboard side with the hooked end of a
suitable pick. Raise end of brush spring only as far as
necessary to free brush from brush holder. Repeat step
to release second brush and then remove brush holder
from field coil.

Inspection

For testing procedures, see the ELECTRICAL DIA-
GNOSTIC MANUAL.

Inspect two o-rings in field coil bore for cuts, tears or signs
of deterioration.

Place armature in lathe or truing stand and check runout
of commutator. Commutators with more than 0.015 in.
(0.38 mm) of runout should be replaced or machined on

2009 Sportster Service: Electrical 6-29

a lathe. Commutators should be replaced when diameter
is less than 1.141 in. (29.98 mm).

Check depth of mica on commutator. If undercut is less
than 0.008 in. (0.20 mm), use an undercutting machine to
undercut the mica to 1/32 in. (0.79 mm) deep. The slots
should then be cleaned to remove any dirt or copper dust.

NOTES

•

See

Figure 6-35

. If an undercutting machine is not avail-

able, undercutting can be done satisfactorily using a thin

hacksaw blade. After undercutting, lightly sand the arma-
ture with crocus cloth to remove any burrs.

•

Do not use sandpaper or emery cloth on commutator. The
abrasive grit may remain on commutator segments and
could cause excessive brush wear.

Inspect armature roller bearings. Bearings must rotate
freely without drag or sticking. Replace the bearings if
pitted or grooved.

Replace brush springs if bent or distorted.

sm02320

Segments

Mica

Incorrect (Mica must not be left with a thin edge next to segments)

Correct (Mica must be cut away clean between segments)

Starting groove in mica with 3 cornered file

Undercutting mica with piece of hacksaw blade

Commutator

Figure 6-35. Undercutting Mica Separators

Assembly

Attach brush holder to field coil. Locate the two brushes
attached to the field coil winding. Catch free end of brush
spring with the hooked end of a suitable pick. Raise end

of brush spring only as far as necessary to install brush
into brush holder. Repeat step to install second brush.

Retract all four brushes for armature installation. For good
results, obtain four paper clips. Bend free end of each
paper clip outward approximately 90°. Then, pushing on

6-30 2009 Sportster Service: Electrical

inboard side of brush, insert straight end of paper clip
between outboard side of brush and inboard side of brush
spring. Properly installed, the paper clip contacts the
framework of the brush holder to keep spring pressure off
the brush. Repeat step on remaining three brushes as
shown in

Figure 6-36

Install armature in solenoid housing so that larger bearing
on splined end seats in counterbore. Lubricate armature
bearings with high temperature grease, such as LUBRI-
PLATE 110, before installation.

Mate field coil and solenoid housings. For proper
assembly, a nub on the field coil housing flange must
engage the slot on solenoid housing flange closest to the
short (field wire) post on the solenoid housing.

Carefully place brush holder over armature. If additional
clearance is needed, use a small flat blade screwdriver to
gently push back the brushes slightly.

When the brush holder is centered over the armature,
remove four paper clips to release brush springs. Verify
that ends of brush springs make proper contact with brush
sides.

Install end cap aligning holes in cap with those in brush
holder. Start two new Phillips screws with captive washers.
Alternately tighten Phillips screws until snug.

Install thru bolts to fasten field coil to solenoid housing.
Using a 5/16 inch socket, alternately tighten thru bolts to
39-65 in-lbs (4.4-7.3 Nm).

Attach field wire ring terminal to short post on solenoid
housing and install hex nut with captive lockwasher.
Tighten hex nut to 70-90 in-lbs (7.9-10.2 Nm). Cover field
wire ring terminal with rubber boot.

10. Install end cover bracket onto threaded end of thru bolts,

if equipped. For proper orientation, be sure that the longest
end of the bracket (before the bend) is on the field wire
side. Install two Keps nuts and alternately tighten until
snug.

11. Install allen head screw to fasten chrome end cover to end

cover bracket, if equipped. Tighten screw to 90-110 in-lbs
(10.2-12.4 Nm).

sm03714

Figure 6-36. Install Paper Clips to Hold Brush Springs

DRIVE ASSEMBLY

Disassembly

Remove field coil. See

6.13 STARTER, Field Coil

Assembly

Pull field coil with end cap from solenoid housing. Hold
end cap to field coil to avoid pulling armature out of brush
holder. If armature is pulled from brush holder, further
disassembly is required.

Using a 9 mm socket, remove two hex screws with Phillips
recess to release drive housing from solenoid housing.

Use a rubber mallet to separate drive and solenoid hous-
ings, if necessary.

Remove idler gear from bearing cage in drive housing.
Remove bearing cage with five steel cylinders from shaft
in drive housing.

Push on end of drive shaft to remove starter clutch
assembly from drive housing.

Compressing internal springs, remove snap ring from
groove at end of drive shaft.

Remove cup, pinion gear, short spring and spring seat
from splined end of drive shaft.

Push on splined end of drive shaft to remove from starter
clutch bore.

10. Remove long spring from drive shaft. Remove steel ball

from drive shaft bore.

11. Remove return spring from solenoid plunger shaft.

Inspection

Inspect two o-rings in drive housing bore for cuts, tears or
signs of deterioration.

Replace springs if kinked, elongated or distorted.

Inspect pinion gear and drive shaft gear. Replace if pitted,
scored, rounded, cracked, chipped or worn.

Inspect roller bearings. Bearings must rotate freely without
drag or sticking. Replace the bearings if pitted or grooved.

Inspect the steel ball for wear, pitting, surface breakdown
or other damage.

Replace snap ring if bent or distorted.

Assembly

Install long spring onto drive shaft. Install steel ball in drive
shaft bore. Insert splined end of drive shaft into starter
clutch bore (gear side).

Insert a deepwell socket into starter clutch bore and stand
assembly upright on work bench with the socket side
down.

Push down on starter clutch, so that installed socket
pushes against the drive shaft gear to compress the spring.
Holding assembly with spring compressed, install spring
seat, short spring, pinion gear and cup on splined end of
drive shaft. Be sure that the collar on the pinion gear and
the concave side of the cup both face the splined end of
the drive shaft.

6.13 STARTER, Field Coil Assembly

2009 Sportster Service: Electrical 6-31

While pushing down to simultaneously compress both the
long and short springs installed, install snap ring in groove
at splined end of drive shaft. Verify that snap ring is fully
seated in the groove and that it resides in concave portion
of cup when spring tension is released.

Remove deepwell socket from starter clutch bore.

Install bearing cage with five steel cylinders onto shaft in
drive housing. Be sure that all five steel cylinders are
installed in grooves of bearing cage. Install idler gear over
bearing cage. Lubricate parts with high temperature
grease, such as LUBRIPLATE 110, during assembly.

Install starter clutch assembly in drive housing seating the
larger bearing in the counterbore. Lubricate bearings with
LUBRIPLATE 110 before installation.

Apply a light film of Lubriplate 110 to solenoid plunger
shaft. Install return spring on solenoid plunger shaft.

Mate the solenoid and drive housings and install two hex
screws using a 9 mm socket. Alternately tighten hex
screws until snug.

10. Lubricate armature bearing with LUBRIPLATE 110.

Seating armature bearing in counterbore, mate field coil
and solenoid housings. For proper assembly, a nub on
the field coil housing flange must engage the slot on
solenoid housing flange closest to the short (field wire)
post on the solenoid housing.

11. Install field coil. See

INSTALLATION

Install starter and starter gasket from right side of motor-
cycle.

1.14 TRANSMISSION LUBRICANT

Figure 6-34

. Install two starter mounting bolts and

washers. Tighten to 13-20 ft-lbs (17.6-27.1 Nm).

Install positive (+) battery cable and solenoid wire to
solenoid stud. Tighten nut to 60-85 in-lbs (6.8-9.6 Nm).
Place rubber boot securely over terminal.

Install primary cover. See

5.3 PRIMARY CHAIN

ADJUSTER

Fill primary chaincase / transmission with proper lubricant;
see

for details.

Install rear exhaust pipe and muffler. See

4.15 EXHAUST

SYSTEM: XL MODELS

4.16 EXHAUST SYSTEM: XR

MODELS

Open left side cover. See

Connect positive (+) battery cable to battery positive (+)
terminal. See

. Close left

side cover.

Connect negative (-) battery cable to stud on engine
crankcase behind starter motor assembly. See

6.13 STARTER, Field Coil Assembly

6-32 2009 Sportster Service: Electrical

6.14

STARTER SOLENOID

SOLENOID ASSEMBLY

Disassembly

Remove field coil. See

6.13 STARTER, Field Coil

Assembly

Pull field coil with end cap from solenoid housing. Hold
end cap to field coil to avoid pulling armature out of brush
holder. If armature is pulled from brush holder, further
disassembly is required.

Using a 9 mm socket, remove two hex screws with Phillips
recess to release solenoid housing from drive housing.

Use a rubber mallet to separate solenoid and drive hous-
ings, if necessary.

Remove return spring from solenoid plunger shaft.

Assembly

Install return spring on solenoid plunger shaft.

Mate the solenoid and drive housings and install two hex
screws using a 9 mm socket. Alternately tighten hex
screws until snug.

Lubricate armature bearing with LUBRIPLATE 110.
Seating armature bearing in counterbore, mate field coil
and solenoid housings. For proper assembly, a nub on
the field coil housing flange must engage the slot on
solenoid housing flange closest to the short (field wire)
post on the solenoid housing.

Install field coil. See

SOLENOID PLUNGER

Disassembly

Remove three hex screws to release solenoid cover.

Remove rubber gasket from solenoid cover flange.

Remove plunger and return spring.

Assembly

Apply a light film of LUBRIPLATE 110 to plunger shaft and
install return spring. Install plunger in solenoid.

Install new rubber gasket on solenoid cover flange.

Install three hex screws to secure solenoid cover. Altern-
ately tighten hex screws until snug.

SOLENOID CONTACTS

Disassembly

Remove three hex screws to release solenoid cover.

Remove rubber gasket from solenoid cover flange.

Remove plunger and return spring.

Obtain Solenoid Contact Repair Kit.

Disassemble short post (field coil):

See

Figure 6-37

. Remove hex nut from post, if still

installed. Remove jam nut, wave washer, round
bushing and o-ring from post.

On inside of solenoid housing, remove post bolt, hold-
in terminal, contact plate and square bushing.

Disassemble long post (battery):

Remove hex nut from post, if still installed. Remove
jam nut, wave washer, round bushing and o-ring from
post.

On inside of solenoid housing, remove post bolt,
contact plate, square bushing and paper insulator
washer.