Harley Davidson Sportster Models 2009. Service Repair Manual - page 58

12. Oil flows through the feed galley in the crankcase to the

tappet blocks and hydraulic lifters. Cross-drilled pas-
sages intersect the main feed galley and carry oil to each
hydraulic lifter. From this cavity, oil is also fed to the piston
jets.

13. Also from the feed galley in the crankcase, oil flows

through a cross drilled passage to the check valve
assembly and to the cylinder heads through flexible lines.
Oil across the cylinder heads and through passages that
surround the exhaust ports. Oil exits each cylinder head
near the exhaust port.

14. Oil exiting the heads flows to the return oil manifold

where it is mixed with the scavenge oil from the scavenge
pump (25) and is pushed back to the tank.

15. Also from the feed galley in the crankcase, oil enters an

intersecting passage in the oil pump body and cam
support. Oil flow is then routed to the outer bearing of
the rear intake camshaft. A cast-in passage allows oil into
a cavity that surrounds the end of the pinion gear shaft.

16. From the same cavity near the end of the pinion shaft, oil

enters the center hole in the oil pump rotor cover which
intersects with a passage that carries oil to the outer
bearings of the front intake camshaft and rear exhaust
camshaft and is used to lubricate the cam bearings.

17. The outer bearing of the front exhaust camshaft is lubric-

ated through a drilled passage that intersects with the
feed galley.

18. Crankcase end of bearings of the cams are fed through

holes in the camshaft.

19. A small amount of oil flows from the feed galley in the right

crankcase through a restricted orifice, which sprays the
oil onto the rear intake cam gear in the gearcase. Oil is
transferred to the teeth of all the cam gears through the
gear meshing action.

20. Oil enters a hole in the end of the pinion gear shaft and

travels to the right flywheel where it is routed through the
flywheel to the crank pin. Oil is forced through the crank
pin to properly lubricate the rod bearing assembly.

21. Oil flows up passages in the push rods to the rocker arm

shafts and bushings.

22. The valve stems are lubricated by oil supplied through

drilled oil holes in the rocker arms.

23. Oil collected in the push rod areas of the cylinder heads

flows down the push rod covers, through drain holes in
the tappet blocks and into the gearcase. After providing
lubrication to the gearcase components the oil settles to
the bottom of the gearcase where the scavenge pump will
collect it.

24. Feed oil to the rocker area is returned to the gearcase

through a passage in the cylinder head, cylinder, and
crankcase.

25. Oil collected in the sump is splash-fed to the pistons, cyl-

inder walls and flywheel components.

26. Oil collected in the sump area returns to the scavenge

pump through an internal passage located in the rear
section of the sump housing. Oil flow to the pump is

accomplished by the scavenging effect of the pump and
by the pressure created by the downward stroke of the
pistons.

27. Oil collected in the gearcase passes through a passage

in the oil pump body and cam support and is also collected
by the scavenge pump.

28. The scavenge pump pushes the collected oil back to the

oil tank.

29. Crankcase vents to oil tank.

HOME

3-24  2009 Sportster Service: Engine

1

17

16

1

2

17

13

14

18

13

11

8

4

14

7

5

3

6

16

10

15

9

18

8

13

11

12

14

10

sm04243

Figure 3-12. Lubrication Diagram: XL Models (Red=Feed Oil, Blue=Return Oil)

Figure 3-12.

Figure 3-12.

Lubrication Diagram: XL Models (Red=Feed Oil, Blue=Return

Oil)

Lubrication Diagram: XL Models (Red=Feed Oil, Blue=Return

Oil)

1

1

25

27

25

26

26

3

5

2

3

6

13

13

4

4

4

18

27

27

22

14

14

14

20

12

8

22

11

6

9

7

10

25

19

24

15

15

19

17

16

18

12

28

22

20

21

23

19

sm05338

Figure 3-13. Lubrication Diagram: XR Models (Red=Feed Oil, Blue=Return Oil)

Figure 3-13.

Figure 3-13.

Lubrication Diagram: XR Models (Red=Feed Oil, Blue=Return

Oil)

Lubrication Diagram: XR Models (Red=Feed Oil, Blue=Return

Oil)

3.9

HOW TO USE THIS SECTION

TYPICAL SYMPTOMS

Symptoms indicating a need for engine repair are often mis-
leading, but generally if more than one symptom is present,
possible causes can be narrowed down to make at least a
partial diagnosis. An above normal consumption of oil, for
example, could be caused by several mechanical faults (see

1.35 TROUBLESHOOTING

). But when accompanied by a

blue-gray smoke from the exhaust, and when low compression
is present, it indicates the rings need replacing. Low compres-
sion by itself, however, indicates improperly seated valves, not
worn rings.

Certain knocking noises may be caused by loose bearings,
others by piston slap, a condition where piston or cylinder or
both out of tolerance, allowing the piston to slap from front to
rear of the cylinder as it moves up and down.

Most frequently, valves, rings, pins, bushings, and bearings
need attention at about the same time. If the symptoms can
be narrowed down through the process of elimination to indicate
that any one of the above components is worn, it is best to give
attention to all of the cylinder head and cylinder parts.

TOP END REPAIR

NOTE

During top end disassembly, the engine may be left in the
chassis for service.

If servicing only cylinder head components, pistons, cylinders
and/or upper rod bushings, see 

3.10 TOP END SERVICE

. Two

options are available depending upon engine status.

•

3.10 TOP END SERVICE, Engine in Chassis

.

•

3.10 TOP END SERVICE, Engine Removed from Chassis

.

BOTTOM END REPAIR

NOTE

Servicing components in the cam compartment requires only
partial disassembly. This can be done with the engine left in
the chassis.

After disassembling as far as the cylinder heads you may find
that bottom end repair is necessary. Bottom end service may
require either partial or complete disassembly of the engine.

•

To service the cam compartment, see 

3.11 BOTTOM END

SERVICE, Engine in Chassis

.

•

To service components in the flywheel compartment, the
engine must be removed and the crankcase halves split.
See 

3.11 BOTTOM END SERVICE, Engine Removed

From Chassis

.

HOME

2009 Sportster Service: Engine  3-29

3.10

TOP END SERVICE

ENGINE IN CHASSIS

Table 3-24. Engine in Chassis

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove parts necessary to gain access to all components above cylinder deck. See

3.15 TOP END OVERHAUL: DISASSEMBLY, Stripping Motorcycle for Top End
Repair

.

Continue with 

3.15 TOP END OVERHAUL: DISASSEMBLY

. Remove/repair sub-

assembly components only if necessary.

*Inspect and repair as necessary. See

3.5 CRANKCASE BREATHING SYSTEM:
XL MODELS

 or 

3.6 CRANKCASE

BREATHING SYSTEM: XR MODELS

.

Remove rocker arm outer covers. Remove crankcase breathers. See 

3.15 TOP END

OVERHAUL: DISASSEMBLY, Cylinder Heads

.

*Inspect and repair as necessary. See

3.21 CYLINDER HEAD

.

Remove cylinder heads. See 

3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder

Heads

.

*Inspect and repair as necessary. See

3.19 VALVE TAPPETS

.

Remove push rods, push rod covers and tappet covers. See 

3.15 TOP END OVER-

HAUL: DISASSEMBLY, Cylinder Heads

. Remove tappets. See 

3.19 VALVE TAPPETS,

Removal

.

*Inspect and repair as necessary. See

3.22 CYLINDER AND PISTON

.

Remove cylinders and pistons. See 

3.15 TOP END OVERHAUL: DISASSEMBLY,

Cylinder and Piston

.

Inspect upper connecting rod and repair
as necessary. See 

3.22 CYLINDER AND

PISTON, Connecting Rod Bushings

.

Complete all appropriate steps under 

3.16 TOP END OVERHAUL: ASSEMBLY

.

Complete motorcycle assembly. See 

3.16 TOP END OVERHAUL: ASSEMBLY,

Assembling Motorcycle After Top End Repair

.

* When this step is completed during top end service, you may advance to 

3.16 TOP END OVERHAUL: ASSEMBLY

. if no other

work is to be done.

HOME

3-30  2009 Sportster Service: Engine

ENGINE REMOVED FROM CHASSIS

Table 3-25. Engine Removed from Chassis

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove engine from chassis. See 

3.12 REMOVING ENGINE FROM CHASSIS

.

Start 

3.15 TOP END OVERHAUL: DISASSEMBLY

. Remove and repair subassembly

components as necessary.

*Inspect and repair as necessary. See

3.5 CRANKCASE BREATHING SYSTEM:
XL MODELS

 or 

3.6 CRANKCASE

BREATHING SYSTEM: XR MODELS

.

Remove rocker arm outer covers. Remove crankcase breathers. See 

3.15 TOP END

OVERHAUL: DISASSEMBLY, Cylinder Heads

.

*Inspect and repair as necessary. See

3.21 CYLINDER HEAD

.

Remove cylinder heads. See 

3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder

Heads

.

*Inspect and repair as necessary. See

3.19 VALVE TAPPETS

.

Remove push rods, push rod covers and tappet covers. See 

3.15 TOP END OVER-

HAUL: DISASSEMBLY, Cylinder Heads

. Remove tappets. See 

3.19 VALVE TAPPETS,

Removal

.

*Inspect and repair as necessary. See

3.22 CYLINDER AND PISTON

.

Remove cylinders and pistons. See 

3.15 TOP END OVERHAUL: DISASSEMBLY,

Cylinder and Piston

.

Inspect upper connecting rod and repair
as necessary. See 

3.22 CYLINDER AND

PISTON, Connecting Rod Bushings

.

Complete all appropriate steps under 

3.16 TOP END OVERHAUL: ASSEMBLY

.

Install engine in motorcycle. Complete all appropriate steps under 

3.13 INSTALLING

ENGINE IN CHASSIS

.

Complete motorcycle assembly. See 

3.16 TOP END OVERHAUL: ASSEMBLY,

Assembling Motorcycle After Top End Repair

.

* When this step is completed during top end service, you may advance to 

3.16 TOP END OVERHAUL: ASSEMBLY

. if no other

work is to be done.

HOME

2009 Sportster Service: Engine  3-31

3.11

BOTTOM END SERVICE

ENGINE IN CHASSIS

Table 3-26. Engine in Chassis: Cam Compartment Service

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove parts necessary to gain access to all components above cylinder deck. See

3.15 TOP END OVERHAUL: DISASSEMBLY, Stripping Motorcycle for Top End
Repair

.

Continue with 

3.15 TOP END OVERHAUL: DISASSEMBLY

. Remove/repair sub-

assembly components only if necessary.

Inspect and repair as necessary. See

3.5 CRANKCASE BREATHING SYSTEM:
XL MODELS

 or 

3.6 CRANKCASE

BREATHING SYSTEM: XR MODELS

.

Remove rocker arm outer covers. Remove crankcase breathers. See 

3.15 TOP END

OVERHAUL: DISASSEMBLY, Cylinder Heads

.

Inspect and repair as necessary. See

3.19 VALVE TAPPETS

.

Remove push rods, push rod covers and tappet covers. See 

3.15 TOP END OVER-

HAUL: DISASSEMBLY, Cylinder Heads

. Remove tappets. See 

3.17 BOTTOM END

OVERHAUL: DISASSEMBLY, Tappets

.

Continue with 

3.17 BOTTOM END OVERHAUL: DISASSEMBLY

.

*Inspect and repair as necessary. See

3.20 GEARCASE COVER AND CAM
GEARS

.

Remove gear case cover and cam gears. See 

3.20 GEARCASE COVER AND CAM

GEARS

.

Inspect and repair as necessary. See

3.24 OIL PUMP: XL MODELS

 or 

3.25 OIL

PUMP: XR MODELS

.

Remove oil pump components. See 

3.24 OIL PUMP: XL MODELS

 or 

3.25 OIL PUMP:

XR MODELS

.

Complete all appropriate steps under 

3.18 BOTTOM END OVERHAUL: ASSEMBLY

.

Complete motorcycle assembly. See 

3.16 TOP END OVERHAUL: ASSEMBLY,

Assembling Motorcycle After Top End Repair

.

* When this step is completed during bottom end service, you may advance to 

3.18 BOTTOM END OVERHAUL: ASSEMBLY

.

if no other work is to be done.

HOME

3-32  2009 Sportster Service: Engine

ENGINE REMOVED FROM CHASSIS

Table 3-27. Engine Removed from Chassis: Flywheel Compartment Service or Complete Engine Overhaul

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove engine from chassis. See 

3.12 REMOVING ENGINE FROM CHASSIS

.

Start 

3.15 TOP END OVERHAUL: DISASSEMBLY

. Remove and repair subassembly

components as necessary.

Inspect and repair as necessary. See

3.5 CRANKCASE BREATHING SYSTEM:
XL MODELS

 or 

3.6 CRANKCASE

BREATHING SYSTEM: XR MODELS

.

Remove rocker arm outer covers. Remove crankcase breathers. See 

3.15 TOP END

OVERHAUL: DISASSEMBLY, Cylinder Heads

.

Inspect and repair as necessary. See

3.21 CYLINDER HEAD

.

Remove cylinder heads. See 

3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder

Heads

.

Inspect and repair as necessary. See

3.19 VALVE TAPPETS

.

Remove push rods, push rod covers and tappet covers. See 

3.15 TOP END OVER-

HAUL: DISASSEMBLY, Cylinder Heads

. Remove tappets. See 

3.17 BOTTOM END

OVERHAUL: DISASSEMBLY, Tappets

.

Inspect and repair as necessary. See

3.22 CYLINDER AND PISTON

.

Remove cylinders and pistons. See 

3.15 TOP END OVERHAUL: DISASSEMBLY,

Cylinder and Piston

.

Inspect upper connecting rod and repair
as necessary. See 

3.22 CYLINDER AND

PISTON, Connecting Rod Bushings

.

Continue with 

3.17 BOTTOM END OVERHAUL: DISASSEMBLY

. Remove and repair

subassembly components as necessary.

Inspect and repair as necessary. See

3.20 GEARCASE COVER AND CAM
GEARS

.

Remove gearcase cover and cam gears. See 

3.20 GEARCASE COVER AND CAM

GEARS

.

Inspect and repair as necessary. See

3.24 OIL PUMP: XL MODELS

 or 

3.25 OIL

PUMP: XR MODELS

.

Remove oil pump. See 

3.24 OIL PUMP: XL MODELS

 or 

3.25 OIL PUMP: XR

MODELS

.

Inspect and repair as necessary. See

3.23 CRANKCASE

.

Complete all appropriate steps under 

3.17 BOTTOM END OVERHAUL: DISAS-

SEMBLY, Crankcase

 to split crankcases and remove flywheel assembly, piston jets,

etc.

Inspect and repair transmission assembly
as necessary. See 

5.10 TRANSMISSION

REMOVAL AND DISASSEMBLY

,

5.11 TRANSMISSION ASSEMBLY

,

5.15 TRANSMISSION INSTALLATION

and related subjects.

Complete all appropriate steps under 

3.18 BOTTOM END OVERHAUL: ASSEMBLY

.

Complete all appropriate steps under 

3.16 TOP END OVERHAUL: ASSEMBLY

.

Install engine in motorcycle. Complete all appropriate steps under 

3.13 INSTALLING

ENGINE IN CHASSIS

.

Complete motorcycle assembly. See 

3.16 TOP END OVERHAUL: ASSEMBLY,

Assembling Motorcycle After Top End Repair

.

HOME

2009 Sportster Service: Engine  3-33

3.12

REMOVING ENGINE FROM CHASSIS

GENERAL

If it becomes necessary to remove the engine from the motor-
cycle, follow the step-by-step procedure below. It is important
to follow the procedure as outlined, particularly in the areas of
stabilizer link and engine mount disassembly.

PROCEDURE: XL MODELS

TOOL NAME

PART NUMBER

SHOP DOLLY

HD-45967

FAT JACK

HD-45968

ENGINE HOOK

HD-46284

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)

1

3

2

4

sm01471

1.

Cylinder head bracket

2.

Washer (2)

3.

Screw (2)

4.

Horn assembly

Figure 3-14. Horn and Cylinder Head Bracket (Models With

Side Mounted Horn Only)

1.

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

4.6 FUEL TANK: XL MODELS

.

2.

Remove seat.

3.

Remove left side cover. See 

2.20 LEFT SIDE COVER

.

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

4.

Disconnect negative (-) battery cable from ground stud on
crankcase. Disconnect positive (+) battery cables at bat-
tery. See 

1.17 BATTERY MAINTENANCE

.

5.

Drain primary chaincase/transmission fluid. See

1.14 TRANSMISSION LUBRICANT

.

6.

Drain oil tank. See 

1.6 ENGINE OIL AND FILTER

. Do not

install drain plug back in end of drain hose at this time.

7.

Unplug O2 sensor connectors [137], [138] and remove
exhaust pipes and mufflers. See 

4.15 EXHAUST SYSTEM:

XL MODELS

.

8.

Remove right front footrest assembly and rear brake
linkage.

a.

Models equipped with mid-mount foot controls:
see 

2.40 RIDER FOOT CONTROLS: XL MODELS

EQUIPPED WITH MID-MOUNT CONTROLS

.

b.

Models equipped with forward foot controls: see

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS

.

9.

Remove screw, washer and exhaust pipe clamp bracket
from sprocket cover. Remove two screws securing
sprocket cover to engine case. Remove sprocket cover.

10. Loosen rear axle nut and move rear axle all the way for-

ward. Tighten axle nut enough to hold the axle and wheel
in position in the rear fork. Remove rear drive belt from
transmission sprocket. See 

5.7 DRIVE BELT

.

11. Remove transmission sprocket. See 

5.16 TRANSMISSION

SPROCKET

.

12. Remove exhaust system interconnect. See 

4.15 EXHAUST

SYSTEM: XL MODELS

.

13. Disconnect oil tank feed, drain and return hoses from oil

tank. See 

3.27 OIL TANK

. Pull drain hose up through drain

hose sleeve in rear of engine crankcase and remove hose
from vehicle.

14. Drain and remove fuel tank. See 

4.6 FUEL TANK: XL

MODELS

.

15. Models with side mounted horn: unplug wiring harness

connectors from horn. See 

Figure 3-14

. Remove two

screws (3) and washers (2). Remove cylinder head bracket
(1) with horn (4) from cylinder heads as a unit.

16. Models with front mounted horn: unplug horn con-

nectors and remove horn from horn bracket. See

6.37 HORN

.

17. Remove air cleaner cover, air filter and air cleaner backing

plate. See 

4.4 AIR CLEANER: XL MODELS

. California

models: remove EVAP purge hose from induction module.

HOME

3-34  2009 Sportster Service: Engine

See 

4.21 EVAPORATIVE EMISSIONS CONTROL (CA

MODELS)

.

18. See 

4.10 INDUCTION MODULE: XL MODELS

 and unplug

the following connectors from the induction module:

a.

Fuel injector connectors [84], [85].

b.

Temperature/Manifold absolute pressure (TMAP)
sensor connector [80].

c.

Idle Air Control (IAC) connector [87].

d.

Throttle Position (TP) sensor connector [88].

19. Unplug the following electrical connectors from the engine:

a.

Ground wire at powertrain ground stud on crankcase.

b.

Spark plug wires.

c.

Oil pressure switch connector [120]. See 

6.36 OIL

PRESSURE SWITCH

.

d.

Crank position (CKP) sensor connector [79]. See

6.28 CRANK POSITION SENSOR (CKP)

.

e.

Alternator AC connector [46]. See 

6.3 VOLTAGE

REGULATOR

.

f.

Neutral indicator switch connector [136]. See

6.31 NEUTRAL INDICATOR SWITCH

.

g.

Vehicle speed sensor (VSS) connector [65]. See

6.30 VEHICLE SPEED SENSOR (VSS)

.

h.

Starter relay wire (GN) at starter motor. See

6.13 STARTER

.

i.

Engine Temperature (ET) sensor connector [90]. Cut
and remove barbed cable strap securing sensor har-
ness to H-bracket. See 

4.9 ENGINE TEMPERATURE

(ET) SENSOR

.

20. Disconnect clutch cable and remove from clutch lever on

left handlebar. See 

2.31 CLUTCH CONTROL

. Remove

cable clips securing clutch cable to frame left front down-
tube.

21. Remove push-in fastener securing right wire harness

caddy to coil bracket. Discard push-in fastener. Remove
screw securing ignition switch to coil bracket. Unplug spark
plug wires from coil. Unplug ignition coil harness connector
[83] from coil. Remove coil and bracket from frame. See

6.19 IGNITION COIL

.

22. Remove screw securing left wire harness caddy to right

wire harness caddy. Separate caddies. See 

6.33 ELEC-

TRICAL CADDIES, Wire Harness Caddy: XL Models

.

23. Unplug the following harness connectors located in the

wire harness caddies:

a.

Instruments connector [20].

b.

Headlamp connector [38].

c.

Right hand control connector (black) [22].

d.

Left hand control connector (gray) [24].

e.

Front turn signal connector [31].

24. Slide left wire harness caddy between frame and engine,

toward right side of vehicle. Move wire harness caddies
and wiring harnesses out of the way.

25. Remove induction module and intake manifold as a unit.

See 

4.10 INDUCTION MODULE: XL MODELS

. Secure

induction module/intake manifold assembly and throttle
cables out of the way.

26. California models: remove EVAP canister and disconnect

hoses. See 

4.21 EVAPORATIVE EMISSIONS CONTROL

(CA MODELS)

.

27. See 

Figure 3-15

. Remove screws (3, 4), grounding strap

(2), stabilizer link (1) and spacer (5).

5

4

3

2

1

sm03428

1.

Stabilizer link

2.

Grounding strap

3.

Screw

4.

Screw

5.

Spacer

Figure 3-15. Rear Stabilizer Link Assembly: Typical (XL

Model Shown)

28. See 

Figure 3-16

. Remove upper stabilizer link (2) and

upper frame bracket (3):

a.

Remove screw (4) securing stabilizer link to engine
bracket (1).

b.

Remove screws (5) and washers (8). Remove horn
bracket (9) (models with front mounted horn) and
upper stabilizer link bracket with stabilizer link.

29. See 

Figure 3-17

. Remove lower stabilizer link (1) and

lower frame bracket (2):

a.

Remove screw (3) securing stabilizer link to engine
crankcase boss.

b.

Remove screws (4), washers (5) and lower frame
bracket with stabilizer link.

HOME

2009 Sportster Service: Engine  3-35

30. Remove rider left footrest and mounting bracket assembly

and shift lever.

a.

Models equipped with mid-mount foot controls:
see 

2.40 RIDER FOOT CONTROLS: XL MODELS

EQUIPPED WITH MID-MOUNT CONTROLS

.

b.

Models equipped with forward foot controls: see

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS

.

4

7

9

5

8

6

1

2

3

4

sm03439

1.

Engine bracket

2.

Upper stabilizer link

3.

Upper frame bracket

4.

Screw

5.

Screw (2)

6.

Screw (2)

7.

Lock washer (2)

8.

Washer (2)

9.

Horn bracket (models with front mounted horn)

Figure 3-16. Upper Front Stabilizer Link Assembly:Typical

(XL Model Shown)

4

5

2

1

3

sm03440

1.

Lower stabilizer link

2.

Lower frame bracket

3.

Screw (2)

4.

Screw (2)

5.

Washer (2)

Figure 3-17. Lower Front Stabilizer Link Assembly:Typical

(XL Model Shown)

31. Models equipped with passenger foot rests: remove

left passenger footrest and mounting bracket assembly.
See 

2.43 PASSENGER FOOTRESTS

.

NOTE

When removing rear brake master cylinder reservoir and
securing it out of the way in the next step, make sure to keep
the reservoir upright. If the reservoir is allowed to hang upside
down, air bubbles could be introduced into the rear master
cylinder via the feed hose. If this happens, the rear brake must
be bled to remove all air from the hydraulic brake system. See

1.8 BLEEDING HYDRAULIC BRAKE SYSTEM

.

32. Remove rear brake master cylinder remote reservoir. Do

not disconnect hose from reservoir. See 

2.15 REAR

BRAKE MASTER CYLINDER RESERVOIR

. Secure

reservoir upright, out of the way.

33. Remove rear stop lamp switch from battery tray. Unplug

rear stop lamp switch connectors [121].

Remove screw and p-clamp securing rear brake hose to
battery tray.

Carefully pull rear stop lamp switch and brake lines out of
the way. Be careful not to bend or kink metal brake lines.
See 

6.27 REAR STOP LAMP SWITCH

.

HOME

3-36  2009 Sportster Service: Engine

1

1

2

3

7

6

5

4

8

8

9

10

11

12

14

13

7

sm04963

11.

6.

1.

Screw (2)

Screw (3)

Bolt (2)

2.

12.

7.

Rear isolator mount

Nut

Rear isolator (2)

8.

3.

13.

Front isolator (2)

Screw (2)

Screw

14.

9.

4.

J-clip (2)

Front isolator mount

Rear fork pivot shaft

5.

10.

Rear pivot lockplate

Front mount bolt

Figure 3-18. Engine Mount/Isolator Components (typical)

34. With the aid of a FAT JACK (Part No. HD-45968), support

motorcycle on SHOP DOLLY (Part No. HD-45967).

35. See 

Figure 3-18

. Remove fasteners (13) and j-clip (14)

from each side of frame.

36. Loosen, but do not remove, two front isolator mounting

bracket screws (11) on left side of engine.

37. Loosen, but do not remove, two rear isolator mounting

bracket screws (3) on left side of engine.

38. Attach ENGINE HOOK (Part No. HD-46284) and engine

hoist. Carefully raise engine enough to relieve pressure
from mounting bolts.

39. Remove front engine mount bolt (10) and nut (12).

40. Remove two screws (11) and front isolator mount (9).

41. Remove two rear engine mount/rear fork pivot bolts (1).

Pull rear fork back until fork pivot bosses clear the frame.

42. Remove oil tank vent hose from oil tank. See 

3.27 OIL

TANK

.

43. Remove two screws (3) and rear isolator mounting bracket

(2) from frame.

44. Lift engine as necessary and swing assembly out from

chassis toward the left side. Swing rear of engine out first.
Then remove engine from chassis.

HOME

2009 Sportster Service: Engine  3-37

PROCEDURE: XR MODELS

TOOL NAME

PART NUMBER

SHOP DOLLY

HD-45967

FAT JACK

HD-45968

ENGINE HOOK

HD-46284

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)

2

3

1

sm04923

1.

Fastener, to induction module

2.

Fastener, to cylinder head (2)

3.

Fastener, wire form

Figure 3-19. Induction Module Cover and Wire Form

1.

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

4.7 FUEL TANK: XR MODELS

.

2.

Remove seat. See 

2.39 SEAT: XR MODELS

.

3.

Remove left side cover. See 

2.20 LEFT SIDE COVER

.

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

4.

Disconnect negative (-) battery cable from ground stud on
crankcase. Disconnect positive (+) battery cables at bat-
tery. Remove battery. See 

1.17 BATTERY MAINTEN-

ANCE

.

5.

Drain primary chaincase/transmission fluid. See

1.14 TRANSMISSION LUBRICANT

.

6.

Drain oil tank. See 

1.6 ENGINE OIL AND FILTER

. Do not

install drain plug back in end of drain hose at this time.

7.

See 

Figure 3-19

. Remove fasteners (1, 2, 3) and remove

induction module cover. Cut tie strap securing TP sensor
harness to side plate.

8.

Disconnect O2 sensor connectors [137], [138] and remove
exhaust pipes and mufflers as an assembly. See

4.16 EXHAUST SYSTEM: XR MODELS

.

9.

Remove these parts if present:

a.

California models: remove EVAP canister and dis-
connect hoses. See 

4.21 EVAPORATIVE EMIS-

SIONS CONTROL (CA MODELS)

.

b.

All other models: remove siren if equipped. See

6.35 OPTIONAL SECURITY SIREN

.

10. See 

Figure 3-20

. Remove two fasteners (1) retaining

siren/canister mount plate and brake line (2) retainer.

11. Remove three screws securing sprocket cover to engine

case. Remove sprocket cover.

12. Remove belt guard and debris deflector from rear fork.

13. Remove fastener securing right shock absorber to the rear

fork.

14. Loosen rear axle nut and move rear axle all the way for-

ward. Tighten axle nut enough to hold the axle and wheel
in position in the rear fork. Remove rear drive belt. See

5.7 DRIVE BELT

.

15. Remove transmission sprocket only if transmission or

engine are to be disassembled. See 

5.16 TRANSMISSION

SPROCKET

.

16. Disconnect rear stop lamp switch connectors [121].

17. Remove rear brake line from clamps at the bottom of left

rear fork.

NOTE

When securing rear master cylinder out of the way in the next
step, make sure to keep the reservoir upright. If the reservoir
is allowed to hang upside down, air bubbles could be introduced
into the rear master cylinder. If this happens, the rear brake
must be bled to remove all air from the hydraulic brake system.

18. See 

Figure 3-21

. Remove fasteners (1) and remove rider's

right footrest including master cylinder assembly and rear
brake linkage. Be careful not to bend or kink metal brake
line and remove assembly out left side of motorcycle. Tie
assembly, with master cylinder upright, out of the way.

19. Disconnect oil tank feed, drain and return hoses from oil

tank. See 

3.27 OIL TANK

. Pull drain hose up through drain

hose sleeve in rear of engine crankcase and remove hose
from vehicle.

20. Unplug horn connectors and remove horn from horn

bracket. See 

6.37 HORN

.

21. Remove fasteners securing air cleaner to fuel tank. Drain

and remove fuel tank. See 

4.7 FUEL TANK: XR MODELS

.

22. Remove air cleaner from induction module as an

assembly. See 

4.5 AIRBOX: XR MODELS

. California

models: remove EVAP purge hose from induction module.
See 

4.21 EVAPORATIVE EMISSIONS CONTROL (CA

MODELS)

.

HOME

3-38  2009 Sportster Service: Engine

23. See 

4.11 INDUCTION MODULE: XR MODELS

 and unplug

the following connectors from the induction module:

a.

Fuel injector connectors [84], [85].

b.

Temperature/Manifold absolute pressure (TMAP)
sensor connector [80].

c.

Idle Air Control (IAC) connector [87].

d.

Throttle Position (TP) sensor connector [88].

24. Unplug the following electrical connectors from the engine:

a.

Ground wire at powertrain ground stud on crankcase.

b.

Spark plug wires.

c.

Oil pressure switch connector [120]. See 

6.36 OIL

PRESSURE SWITCH

.

d.

Crank position (CKP) sensor connector [79]. See

6.28 CRANK POSITION SENSOR (CKP)

.

e.

Alternator AC connector [46] and DC connector [77].
See 

6.3 VOLTAGE REGULATOR

.

f.

Neutral indicator switch connector [136]. See

6.31 NEUTRAL INDICATOR SWITCH

.

g.

Vehicle speed sensor (VSS) connector [65]. See

6.30 VEHICLE SPEED SENSOR (VSS)

.

h.

Starter relay wire (GN) at starter motor. See

6.13 STARTER

.

i.

Engine Temperature (ET) sensor connector [90]. Cut
and remove barbed cable strap securing sensor har-
ness to H-bracket. See 

4.9 ENGINE TEMPERATURE

(ET) SENSOR

.

25. If equipped, disconnect jiffy stand sensor connector [133]

and remove sensor. See 

6.34 JIFFY STAND SWITCH:

INTERNATIONAL MODELS

.

26. Disconnect clutch cable and remove from clutch lever on

left handlebar. See 

2.31 CLUTCH CONTROL

. Remove

cable from oil cooler mount and clips securing clutch cable
to left front downtube.

27. See 

Figure 3-22

. Remove oil cooler fasteners (1) from

frame mounts (2) and remove oil cooler. It is not necessary
to disconnect the oil hoses attached to the oil cooler. Tie
oil cooler to engine.

28. Remove fastener retaining coil bracket to backbone elec-

trical caddy. Remove screw securing ignition switch to coil
bracket. Unplug spark plug wires from coil. Unplug ignition
coil harness connector [83] from coil. Remove coil and
bracket from frame. Position ignition switch out of the way.
See 

6.19 IGNITION COIL

.

29. Remove induction module, leaving cables attached. See

4.11 INDUCTION MODULE: XR MODELS

. Secure

induction module assembly and throttle cables out of the
way.

30. See 

Figure 3-23

. Remove screws (3, 4), grounding strap

(2), stabilizer link (1) and spacer (5).

1

2

sm04977

1.

Fastener, siren/canister mount (2)

2.

Rear brake line

Figure 3-20. Siren/Canister Mount Plate and Brake Line

1

2

sm04976

1.

Fastener, footrest mount (2)

2.

Footrest and master cylinder bracket

Figure 3-21. Right Footrest and Rear Master Cylinder

HOME

2009 Sportster Service: Engine  3-39