Harley Davidson Sportster Models 2009. Service Repair Manual - page 60

See

. Remove hardware securing inner rocker

cover to cylinder head in the following order.

Remove two screws and washers (1).

Remove three bolts and washers (2).

Loosen four rocker arm bolts (3) in 1/4-1/2 turn
increments using a cross pattern. This relieves valve
spring pressure evenly on inner rocker cover.

NOTE

Remove each inner rocker cover as an assembly; then disas-
semble as required.

See

Figure 3-42

. Remove inner rocker cover (8) or (24).

Remove and discard gasket (16).

Remove breather assembly:

XL models: remove screw (6), breather assembly
(7) and breather seal (17). Discard seal.

XR models: push breather assembly (23) and o-ring
(22) out from the under side.

NOTE

Mark rocker arm shafts for reassembly in their original positions.
Valve train components must be reinstalled in their original
positions during reassembly or increased engine wear may
result.

See

Figure 3-44

. Remove rocker arm shafts by tapping

them out using a hammer and a soft metal punch.

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Figure 3-43. Inner Rocker Cover Fasteners (typical - XL

shown)

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Retaining notch

Position of rocker arm retaining bolts

Figure 3-44. Removing Rocker Arm Shafts (typical - XL

shown)

See

Figure 3-42

. Remove rocker arms (11, 12); mark them

for reassembly in their original locations.

10. Repeat these steps for other rocker cover.

Removing Cylinder Head

NOTE

See

Figure 3-45

Figure 3-46

. To avoid distortion of the cyl-

inder head, cylinder and crankcase studs, gradually loosen (or
tighten) head screws in the sequence shown.

XR Models: Remove Precision Cooling lines. See

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

See

Figure 3-45

and

Figure 3-46

. Loosen each head bolt

1/8-turn following the sequence shown.

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3-56 2009 Sportster Service: Engine

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Short bolt

Long bolt

Figure 3-45. Front Cylinder Head Screw

Loosening/Tightening Sequence (typical)

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Short bolt

Long bolt

Figure 3-46. Rear Cylinder Head Screw

Loosening/Tightening Sequence (typical)

Continue loosening in 1/8-turn increments until screws are
loose. Remove head screws.

See

Figure 3-47

. Remove cylinder head (8) and head

gasket (10). Discard head gasket.

Repeat previous steps for other head.

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2009 Sportster Service: Engine 3-57

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12.

Cylinder w/ piston and rings

Head bolt, short (2)

13.

Head bolt, long (2)

Cylinder base gasket

14.

Cylinder base stud (4)

Valve collar retainer (4)

15.

Upper valve spring collar (2)

Valve (1) intake, (1) exhaust

16.

Valve seat (2)

Valve spring (2)

17.

Valve seal and lower valve spring collar assembly
(2)

Cylinder head bracket*

18. Screw (2)*

19.

Valve guide, intake and exhaust (2)

Washer (2)*

20.

Stabilizer link bracket (front cylinder head only)

Cylinder head

21.

Exhaust port stud (2)

Screw (2)

22.

10.

Lock washer (2)

Cylinder head gasket

11. Dowel (2)

Figure 3-47. Cylinder Head, Cylinder and Piston Assembly (typical) (*Models with Side Mounted Horn Only)

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3-58 2009 Sportster Service: Engine

Disassembling Push Rods and Covers

See

Figure 3-48

. Remove push rod covers (2), o-rings (1,

3) and push rods (4). Mark the location and orientation
(top and bottom) of each push rod. Discard o-rings.

Remove socket screws (5) and washers (6). Remove
retainer (7) and gasket (8). Discard gasket.

Repeat above steps for other cylinder.

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O-ring (4)

Push rod cover (4)

O-ring (4)

Push rod (4)

Screw (8)

Washer (8)

Retainer (2)

Gasket (2)

Screw (2)

10. Anti-rotation device (2)
11. Tappet (4)
12. Right crankcase

Figure 3-48. Middle Valve Train Components

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2009 Sportster Service: Engine 3-59

CYLINDER AND PISTON

TOOL NAME

PART NUMBER

PISTON PIN LOCK RING
REMOVER/INSTALLER

HD-34623-C

PISTON PIN REMOVER

HD-42320-A

PISTON SUPPORT PLATE

HD-42322

See

Figure 3-49

. Clean crankcase around base of cylinder

(7) to prevent dirt and debris from entering crankcase while
removing cylinder.

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Piston pin bushing

Connecting rod

Lock ring (2)

Piston pin

Piston ring set

Piston

Cylinder

Cylinder stud (4)

Cylinder base gasket

10. Dowel (2)
11. O-ring (2)
12. Head gasket

Figure 3-49. Cylinder and Piston

Turn engine over until piston (6) of cylinder being removed
is at bottom of its stroke.

Carefully raise cylinder just enough to permit placing clean
towel under piston to prevent any foreign matter from
falling into crankcase.

NOTE

If cylinder does not come loose, tap lightly with rawhide or
plastic hammer perpendicular to cylinder fins. Never try to pry
cylinder up.

Carefully lift cylinder over piston and cylinder studs (8).
Do not allow piston to fall against cylinder studs.

NOTE

To avoid damage to piston assembly and/or cylinder studs, do
not allow piston to fall against studs.

Discard cylinder base gasket (9).

NOTE

With cylinder removed, be careful not to bend the cylinder
studs. The slightest bend could cause a stress riser and could
lead to stud failure.

Install a 6.0 in. (150 mm) length of 1/2 in. (12.7 mm) I.D.
plastic or rubber hose over each cylinder stud. This will
protect the studs and the pistons.

Handle piston with extreme care. The alloy used in these
pistons is very hard. Any scratches, gouges or other marks
in the pistons could score the cylinder during engine
operation and cause engine damage. (00546b)

Wear safety glasses or goggles when removing or
installing piston pin retaining rings. Piston pin retaining
rings are compressed in the ring groove and can fly out
when removed from the groove, which could result in
serious eye injury. (00293a)

See

Figure 3-50

. Remove piston pin lock ring as follows:

I n s e r t P I S TO N P I N L O C K R I N G
REMOVER/INSTALLER (Part No. HD-34623-C) into
piston pin bore until claw on tool is positioned in slot
of piston (directly under lock ring).

Squeeze handles of tool together and pull from bore.
Hold a shop towel over bore during removal in the
event that the lock ring should fly out. Remove lock
ring from claw and discard.

NOTES

•

It is not necessary to remove both piston pin lock rings
during piston removal. Leave second lock ring in piston
pin bore.

•

Do not reuse piston pin lock rings. Removal may weaken
lock rings and they may break or dislodge if reused, res-
ulting in engine damage.

•

See

Figure 3-51

. Piston pin has tapered ends to help seat

the round lock rings.

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3-60 2009 Sportster Service: Engine

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Piston pin lock ring

Piston pin lock ring installer

Figure 3-50. Removing Piston Pin Lock Ring

NOTE

To avoid damage to piston or cylinder base studs, use PISTON
SUPPORT PLATE (Part No. HD-42322) to secure piston in
place while removing piston pin.

Remove piston pin. Since pin is a loose fit in piston, pin
should easily slide out. If pin is difficult to remove, use
PISTON PIN REMOVER (Part No. HD-42320-A), as fol-
lows:

See

Figure 3-52

. Remove acorn nut and spacer (1)

from rod end of tool.

Slide rod end through piston pin. Install spacer and
acorn nut on end of rod.

Position rubber coated tips (2) of tool on flat on each
side of piston pin bore.

Hold tool body (3) and turn handle (4) clockwise until
piston pin is pulled free of bore.

Remove piston from connecting rod. Be sure to hold con-
necting rod shank upright to prevent it from striking
crankcase.

10. Place a 3.0 in. (76.2 mm) length of 1.0 in. (25.4 mm) I.D.

foam-type water pipe insulation around each connecting
rod to prevent damage.

11. Mark each pin boss with either an "F" or an "R" to indicate

front or rear cylinder, respectively.

12. See

Figure 3-53

. Spread piston rings outward until they

clear grooves in piston and lift off.

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Figure 3-51. Tapered Ends on Piston Pin

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Acorn nut and spacer

Rubber coated tip (2)

Tool body

Handle

Figure 3-52. Removing Piston Pin with HD-42320-A Piston

Pin Remover

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Figure 3-53. Removing Piston Rings (typical; XL shown)

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2009 Sportster Service: Engine 3-61

3.16

TOP END OVERHAUL: ASSEMBLY

GENERAL

This section describes assembling the top end of the engine,
from the cylinder deck up. If the engine crankcase has been
disassembled for repair, it must be assembled before assem-
bling the top end of the engine. See

3.18 BOTTOM END

OVERHAUL: ASSEMBLY

PISTON AND CYLINDER

TOOL NAME

PART NUMBER

PISTON PIN LOCK RING
REMOVER/INSTALLER

HD-34623-C

PISTON SUPPORT PLATE

HD-42322

PISTON RING COMPRESSOR

HD-96333-51E

Slide approximately 6.0 in. (152 mm) of plastic tubing,
rubber hose or conduit over each cylinder stud to protect
cylinder studs and piston from damage.

NOTE

See

Figure 3-54

. New 883 cc and 1200 cc pistons must be

installed with the arrows on the top and side of the piston
pointing toward the front of the engine.

Install piston assembly over connecting rod.

Install piston pin.

NOTE

You may wish to place clean shop towels over cylinder and
lifter bores prior to the next step, to prevent the piston pin lock
ring from falling into the crankcase.

See

Figure 3-55

. Install new piston pin lock rings with the

PISTON PIN LOCK RING REMOVER/INSTALLER (Part
No. HD-34623-C). Make sure the ring groove is clean and
that the ring is fully seated in the groove with the gap away
from the slot at the bottom.

NOTE

Avoid damage to cylinder and piston. Always use new lock
ring. Make sure lock ring groove is clean and lock ring seats
firmly in groove. If it does not, discard the lock ring. Never install
a used lock ring or a new one if it has been installed and then
removed for any reason. A loosely installed ring will come out
of the piston groove and damage cylinder and piston beyond
repair.

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Figure 3-54. Arrows on Piston Must Point Toward Front of

Engine (typical; XL shown)

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Figure 3-55. Installing Piston Lock Rings

See

Figure 3-56

. Make sure the piston ring end gaps are

properly positioned as shown.

Lubricate cylinder wall, piston, pin and rod bushing with
engine oil.

Remove cylinder stud sleeves. Install a new cylinder base
gasket. Make sure the piston does not bump the studs or
crankcase.

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3-62 2009 Sportster Service: Engine

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Front

Rear

Piston Pin

Figure 3-56. Position Ring End Gaps at Arrows

See

Figure 3-57

. Install PISTON SUPPORT PLATE (Part

No. HD-42322) as shown. Turn engine to rest piston on
support plate.

See

Figure 3-58

. Compress the piston rings using PISTON

RING COMPRESSOR (Part No. HD-96333-51E).

10. Gently slide cylinder over cylinder base studs and piston

crown, resting it on the top of the ring compressor band
as shown.

11. Push the cylinder down with a firm, quick motion until the

bottom of the cylinder bore slides below the piston ring
area.

12. Remove the piston ring compressor and piston support

plate, and push the cylinder all the way down onto the
crankcase cylinder deck.

13. Repeat above procedure for other piston and cylinder.

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Figure 3-57. Piston Support Plate

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Figure 3-58. Installing Cylinder Over Piston

PUSH RODS, COVERS, AND RETAINERS

See

Figure 3-59

. If anti-rotation devices (10) and tappets

(11) have been removed, install them now. See

3.18 BOTTOM END OVERHAUL: ASSEMBLY, Tappets

Install retainer (7) with new gasket (8). Secure with screws
(5) and washers (6). Tighten to 80-110 in-lbs (9.0-12.4
Nm).

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2009 Sportster Service: Engine 3-63

Install new o-rings (3) in recesses in retainer. Press push
rod covers (2) into o-rings.

Repeat previous steps for other cylinder.

Identify push rod color coding and length, and respective
push rod positions in engine (refer to

Table 3-28

). Slide

intake and exhaust push rods (4) down inside push rod
covers until they rest on seat at top of tappet (11).

Table 3-28. Push Rod Specifications

PART NO.

LENGTH

COLOR CODE

POSITION

IN.

17909-02

27.295

10.746

1 band: orange

Intake (front and rear)

17908-02

27.432

10.800

1 band: purple

Exhaust (front and rear)

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3-64 2009 Sportster Service: Engine

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O-ring (4)

Push rod cover (4)

O-ring (4)

Push rod (4)

Screw (8)

Washer (8)

Retainer (2)

Gasket (2)

Screw (2)

10. Anti-rotation device (2)
11. Tappet (4)
12. Right crankcase

Figure 3-59. Middle Valve Train Components

CYLINDER HEAD

NOTES

•

Push rod covers and lower cover retainers MUST be
installed prior to installing cylinder heads. If this has not
been done, see

3.16 TOP END OVERHAUL: ASSEMBLY,

Push Rods, Covers, and Retainers

•

Thoroughly clean and lubricate threads of cylinder head
screws before installation. Friction caused by dirt and
grime will result in a false torque indication.

See

Figure 3-61

. Coat mating surfaces of cylinder base

studs (14) and head bolts (1 and 2) with parts cleaning
solution.

Scrape old oil and any carbon deposits from threads by
using a back-and-forth motion, threading each head screw
onto its mating cylinder stud.

Remove head bolts from studs. Wipe or blow dry thread
surfaces.

Thoroughly clean and dry gasket surfaces of cylinder (12)
and cylinder head (8).

NOTE

See

Figure 3-60

. The cylinder head gasket is unique for XR

models and has metal patches (2) that must be installed against
the cylinder head. When installing the gasket on the cylinder,
be sure the words "THIS SIDE UP" (1) and the metal patches
(2) are visible.

Install a new head gasket to cylinder.

Carefully lower cylinder head over studs and position on
dowels. Use great care so as not to disturb head gasket.

NOTE

Only oil film must remain on the cylinder head screw surfaces.
Too much oil will pool in the head screw sleeve preventing full
thread engagement.

Lightly coat threads, underside of flange and bottom face
of cylinder head bolts in clean Harley-Davidson 20W50
engine oil. Wipe off excess oil.

Start cylinder head bolts (1 and 2) onto cylinder studs, two
short bolts on left side of engine, two long bolts on right.
Tighten all bolts only finger tight at this time.

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2009 Sportster Service: Engine 3-65

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Words "THIS SIDE UP"

Metal patches

Figure 3-60. Cylinder Head Gasket: XR Models

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3-66 2009 Sportster Service: Engine

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12.

Cylinder w/ piston and rings

Head bolt, short (2)

13.

Head bolt, long (2)

Cylinder base gasket

14.

Cylinder base stud (4)

Valve collar retainer (4)

15.

Upper valve spring collar (2)

Valve (1) intake, (1) exhaust

16.

Valve seat (2)

Valve spring (2)

17.

Valve seal and lower valve spring collar assembly
(2)

Cylinder head bracket*

18. Screw (2)*

19.

Valve guide, intake and exhaust (2)

Washer (2)*

20.

Stabilizer link bracket (front cylinder head only)

Cylinder head

21.

Exhaust port stud (2)

Screw (2)

22.

10.

Lock washer (2)

Cylinder head gasket

11. Dowel (2)

Figure 3-61. Cylinder Head, Cylinder and Piston Assembly (typical) (*Models with Side Mounted Horn Only)

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2009 Sportster Service: Engine 3-67

NOTE

The procedure for tightening the head screws is critical to
proper distribution of pressure over gasket area. It prevents
gasket leaks, stud failure, and head and cylinder distortion.

See

Figure 3-62

and

Figure 3-63

. For each cylinder head,

start with bolt numbered one, as shown. In increasing
numerical sequence (i.e.: 1, 2, 3, 4), tighten head bolts in
the following steps:

Tighten each bolt to 96-120 in-lbs (11-14 Nm).

Tighten each bolt to 13-15 ft-lbs (18-20 Nm).

Loosen all bolts.

10. After head bolts are loosened from initial torque, tighten

bolts in three stages. Tighten in increasing numerical
sequence (i.e.: 1, 2, 3, 4), as follows:

Tighten each bolt to 96-120 in-lbs (11-14 Nm).

Tighten each bolt to 13-15 ft-lbs (18-20 Nm).

See

Figure 3-64

. Mark cylinder head and head bolt

shoulder with a line as shown (View A).

Tighten each bolt an additional 85°-95° (View B).

11. Repeat above procedure for other cylinder head.

12. XR Models: Install Precision Cooling oil lines. See

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

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Short bolt

Long bolt

Figure 3-62. Front Cylinder Head Screw

Loosening/Tightening Sequence (typical)

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Short bolt

Long bolt

Figure 3-63. Rear Cylinder Head Screw

Loosening/Tightening Sequence (typical)

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View A

View B

Figure 3-64. Tightening Head Bolts

ROCKER COVERS

NOTE

Before installing a rocker cover assembly on a cylinder head,
turn engine over so that both lifters for that cylinder are on the
base circle (the lowest position) of the cams.

See

Figure 3-65

. Install new gasket (16), with the bead

facing up. Place inner rocker cover assembly (8) or (24)
(with rocker arms and shafts) into position, fitting ends of
push rods in rocker arm sockets.

NOTE

To avoid damage to push rods or rocker arms, do not turn
engine over until both push rods can be turned with fingers.

Install fasteners (13, 15, 14). Slowly snug all fasteners in
small increments (one turn at a time). Use a cross pattern
on the four large bolts (13) that fasten the inner rocker

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3-68 2009 Sportster Service: Engine

cover to the head. This will bleed the lifters. Tighten
fasteners in the following sequence:

Tighten bolts (13) to 18-22 ft-lbs (24.4-29.8 Nm).

Tighten bolts (15) to 135-155 in-lbs (15.3-17.5 Nm).

Tighten screws (14) to 135-155 in-lbs (15.3-17.5 Nm).

NOTE

XL models: See

Figure 3-65

. Breather location in inner rocker

cover is different between front and rear cylinders.

Install breather:

XL models: Install breather (7) with new breather
seal (17) and secure with screw (6). Tighten to 35-55
in-lbs (4.0-6.2 Nm).

XR models: Install new o-ring (22) on breather
assembly (23) and install in cavity in inner rocker
cover.

Place new gaskets (4, 5) on inner rocker cover.

Install outer rocker cover (3) or (20) on inner rocker cover.
Install screws with captive washers (1) and new sealing
washers (2). Tighten screws to 120-168 in-lbs (13.5-19.0
Nm).

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2009 Sportster Service: Engine 3-69

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13.

Bolt (4)

Screw w/ captive washer (4)

14.

Sealing washer (4)

Screw (2)

15.

Bolt (3)

Outer rocker cover: XL Models

16.

Gasket

17.

Breather seal: XL Models

Gasket

18.

Screw

Breather location: Front Cylinder: XL Models

19.

Breather location: Rear Cylinder: XL Models

Breather assembly: XL Models

20.

Inner rocker cover: XL Models

Outer rocker cover: XR Models

21.

Breather hose fitting hole: XR Models

Rocker arm shaft (2)

10.

22.

Rocker arm bushing (4)

O-ring: XR Models

23.

11.

Breather filter and valve assembly: XR Models

Rocker arm

12.

24.

Rocker arm

Inner rocker cover: XR Models

Figure 3-65. Rocker Cover Assembly

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3-70 2009 Sportster Service: Engine

ASSEMBLING MOTORCYCLE AFTER TOP
END REPAIR

See

Figure 3-66

. Install upper front stabilizer link and frame

bracket:

Install upper frame bracket (3) with upper stabilizer
link (2), horn bracket (9) (models with front mounted
horn), screws (5) and washers (8). Tighten screws to
25-35 ft-lbs (33.9-47.5 Nm).

Install screw (4) securing stabilizer link to engine
bracket (1). Tighten screw to 25-35 ft-lbs (33.9-47.5
Nm).

Install induction module assembly. See

4.10 INDUCTION

MODULE: XL MODELS

4.11 INDUCTION MODULE:

XR MODELS

. Plug the following connectors into the

induction module:

Throttle Position (TP) sensor connector [88].

Idle Air Control (IAC) connector [87].

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

Fuel injector connectors [84], [85].

Install air cleaner assembly:

XL models: Install backing plate, air filter and air
cleaner cover. See

4.4 AIR CLEANER: XL MODELS

XR models: Install airbox assembly and connect
crankcase vent hoses. See

4.5 AIRBOX: XR

MODELS

California models: install EVAP purge hose on
induction module. See

4.21 EVAPORATIVE EMIS-

SIONS CONTROL (CA MODELS)

Models with front mounted horn: install horn. See

6.37 HORN

Models with side mounted horn: See

Figure 3-67

. Install

cylinder head bracket (1) with horn (4) onto cylinder heads
as a unit. Secure with two screws (3) and washers (2).
Tighten screws to 17-24 ft-lbs (23.1-32.6 Nm). Plug wiring
harness connectors into horn.

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)

Install fuel tank. Tighten screws to 15-20 ft-lbs (20.4-27.1
Nm). Attach quick-connect fitting on fuel line to fuel tank
fitting. Gently tug on quick-connect fitting to make sure it
is securely locked in place. See

4.6 FUEL TANK: XL

MODELS

4.7 FUEL TANK: XR MODELS

Install exhaust pipes and mufflers. Plug in O2 sensor
connectors [137], [138]. See

4.15 EXHAUST SYSTEM:

XL MODELS

4.16 EXHAUST SYSTEM: XR MODELS

Connect spark plug cables to spark plugs.

Plug in main fuse. See

6.38 MAIN FUSE

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)

10. Install seat.

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Engine bracket

Upper stabilizer link

Upper frame bracket

Screw

Screw (2)

Lock washer (2)

Washer (2)

Horn bracket (models with front mounted horn)

Figure 3-66. Upper Front Stabilizer Link Assembly (typical)

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2009 Sportster Service: Engine 3-71

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