Harley Davidson Sportster Models 2009. Service Repair Manual - page 62

sm05014

Figure 3-99. Crankshaft Locking Tool (Part No. HD-43984)

6.

Install rear exhaust cam (1). Rotate cam until timing mark
(a slot) points exactly at centerline of rear intake cam bore.

7.

Install front intake cam (3). Rotate cam until slotted timing
mark points exactly at centerline of rear intake cam bore.

NOTE

See 

Figure 3-100

. "V" marks on rear intake cam (2) are not

used for timing of Sportster model engines.

8.

Install rear intake cam (2). As you install this cam, rotate
it so that the three timing marks (dots) line up exactly with
timing marks on the pinion gear, rear exhaust cam and
front intake cam.

9.

Install front exhaust cam (4). As you install this cam, rotate
it so that its timing mark (a dot) lines up with timing mark
(dot) of front intake cam.

NOTE

Make sure all timing marks on cams line up correctly, as shown
in 

Figure 3-100

. If necessary, remove a cam, rotate it slightly,

and re-install it. If timing marks are off even one tooth, engine
will not run correctly.

1

2

3

4

5

sm05013a

1.

Rear exhaust cam gear 1S

2.

Rear intake cam gear 2S

3.

Front intake cam gear 3S

4.

Front exhaust cam gear 4S

5.

Pinion gear

Figure 3-100. Cam, Pinion Gear and Timing Mark Indexing: XR Models (Cam #2 "V" marks are not used for timing)

HOME

3-88  2009 Sportster Service: Engine

10. Lubricate all cam bores in gearcase cover with clean

Harley-Davidson 20W-50 engine oil.

11.

Figure 3-101

. Install gearcase cover with new gasket and

secure with three fasteners (6). Tighten fasteners to 80-
110 in-lbs (9.0-12.4 Nm).

12. Install oil pump rotors. Be sure they are oriented the same

as when they were removed.

13. Install new o-rings in oil pump cover and install using six

fasteners (4). Tighten fasteners to 80-110 in-lbs (9.0-12.4
Nm).

14. Install check valve housing using a new base o-ring.

Tighten fasteners (3) to 84-108 in-lbs (9.5-12.2 Nm).

15. Connect rigid lines (1) and vent hose (2). See 

3.14 PRE-

CISION COOLING SYSTEM: XR MODELS, Oil Pump
Lines

.

16. See 

Figure 3-102

. Install gearcase and oil pump cover.

Secure with 9 socket fasteners. Tighten in the sequence
shown to 80-110 in-lbs (9.0-12.4 Nm).

1

1

5

4

3

2

6

6

sm05004

1.

Rigid lines (4)

2.

Vent hose

3.

Check valve screws (2)

4.

Oil pump cover screw (6)

5.

Oil pump cover

6.

Gearcase cover fastener (3)

Figure 3-101. Gearcase Cover and Oil Pump: XR Models

7

3

1

5

4

2

6

8

9

sm05017

Figure 3-102. Oil Pump Cover Torque Sequence: XR Models

17. Check cam gear end play through tappet bores in right

crankcase, for each cam gear as follows:

a.

Turn engine over until lobe of cam gear being checked
is pointing toward its respective tappet guide hole.

b.

Using a flat blade screwdriver, gently pry cam gear
toward gearcase cover.

c.

Using a feeler gauge, measure gap between bore (in
crankcase) and cam gear shaft thrust face (shoulder).
This is cam gear end play.

d.

Compare your cam gear end play measurements with
the 

3.2 SPECIFICATIONS

. Make repairs as required

if end gap is less than the minimum specified, or
greater than the maximum specified (Service Wear
Limits).

TAPPETS

1.

See 

Figure 3-103

. Rotate engine so that both tappets (3)

from the cylinder being serviced will be installed on the
base circle (lowest position) of the cam.

2.

Apply a liberal amount of engine oil to tappet assembly
(especially roller needles) for smooth initial operation.

3.

Insert both tappets (intake and exhaust) into anti-rotation
device (2) with flats at upper end of each tappet positioned
so they will be facing front and rear when assembly is
installed in engine, and the tappet oil feed hole is facing
toward the gear cover.

4.

Install anti-rotation device with tappets into bore in right
crankcase (4). Secure with screw (1). Tighten to 80-110
in-lbs (9.0-12.4 Nm).

3

2

1

4

sm03422

1.

Screw (2)

2.

Anti-rotation device (2)

3.

Tappet (4)

4.

Right crankcase

Figure 3-103. Tappet Installation

HOME

2009 Sportster Service: Engine  3-89

3.19

VALVE TAPPETS

GENERAL

See 

Figure 3-104

. The tappet assembly consists of tappet and

roller. The tappet and roller, under compression force from
valve spring, follow the surface of the revolving cam. The up-
and-down motion produced is transmitted to the valve by the
push rod and rocker arm. The tappet contains a piston (or
plunger) and cylinder; it also contains a check valve, which
allows the unit to fill with engine oil, thereby reducing clearance
in the valve train.

When a tappet is functioning properly, the assembly operates
with minimal tappet clearance. The unit automatically com-
pensates for heat expansion to maintain a no-clearance condi-
tion.

It is normal for tappets to click when engine is started after
standing for some time. Tappets have a definite leakdown rate
which permits the oil in the tappets to escape. This is necessary
to allow units to compensate for various expansion conditions
of parts and still maintain correct clearance operation. Tappets
are functioning properly if they become quiet after a few
minutes of engine operation.

1

2

1

3

4

sm01597

1.

Oil

2.

Piston

3.

Check valve

4.

Roller

Figure 3-104. Tappet Assembly

REMOVAL

See 

3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Tap-

pets

 to remove tappets from engine.

CLEANING AND INSPECTION

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)

1.

Clean all parts, except roller/tappet assembly, thoroughly
in solvent. Blow dry with compressed air.

2.

Refer to 

Table 3-29

. Inspect valve tappets for excessive

clearance in guide. Accurately measure tappet bore inner
diameter with a gauge. Excessive tappet guide clearance
is corrected by fitting a new tappet and/or replacing
crankcases.

NOTE

Inside and outside micrometers used for measuring tappets
and tappet guides must be calibrated to ensure accurate
readings.

3.

Check tappet roller free play. Recommended service
practice is tappet replacement.

4.

Check tappet roller end clearance.

5.

Tappets should be soaked in clean engine oil and kept
covered until assembly.

Table 3-29. Valve Tappet Specifications

SERVICE WEAR LIMIT

VALUE

ITEM

0.0030 in. (0.076 mm)

0.0008-0.0020 in. (0.020-0.051 mm)

Tappet clearance in guide

0.0015 in. (0.038 mm)

0.0006-0.0010 in. (0.015-0.025 mm)

Tappet roller free play (clearance on pin)

0.026 in. (0.660 mm)

0.008-0.022 in. (0.203-0.559 mm)

Tappet roller end clearance

INSTALLATION

To install tappets, see 

3.18 BOTTOM END OVERHAUL:

ASSEMBLY, Tappets

.

HOME

2009 Sportster Service: Engine  3-91

3.20

GEARCASE COVER AND CAM GEARS

GENERAL

Read the complete gearcase section carefully before you begin
any service work.

For the gearcase components to operate at their optimum, all
components must be properly fitted and matched. Changing
one component can affect many others. It is important to know
and understand all inspection procedures and how components
interact.

REMOVAL AND DISASSEMBLY

See 

3.17 BOTTOM END OVERHAUL: DISASSEMBLY,

Gearcase Cover and Cam Gears: XL Models

 or 

3.17 BOTTOM

END OVERHAUL: DISASSEMBLY, Oil Pump Housing/Gear-
case Cover and Cam Gears: XR Models

 to remove gearcase

cover and cam gears from engine.

CLEANING, INSPECTION AND REPAIR

1.

Thoroughly clean gearcase compartment, gearcase cover
and gears in solvent to remove oil and carbon deposits.

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)

2.

Blow out all gearcase cover oil passages and bushings
with low pressure compressed air.

3.

Clean old gasket material from gearcase and gearcase
cover faces with cleaning solvent.

Cam and Pinion Gear Identification,
Inspection and Selection

See 

Figure 3-105

. Cam lobes are stamped with a number (1,

2, 3, or 4) followed by a letter. The number identifies the cam
location/function:

The letter indicates the cam lobe profile. Use only "W" cams
in all XL models. Use only "S" cams in XR models.

Table 3-30. Cam Identification

XR

XL

CAM LOCATION

1S

1W

Rear Exhaust

2S

2W

Rear Intake

3S

3W

Front Intake

4S

4W

Front Exhaust

NOTE

Prior to changing any cam gears, check gear shaft fit within
corresponding bushings. Worn bushings can cause excessive
backlash.

4W

sm03406

Figure 3-105. Cam Identification (typical; XL shown)

BUSHING INSPECTION AND REMOVAL: XL
ONLY

TOOL NAME

PART NUMBER

BUSHING AND BEARING PULLER

HD-95760-69A

HOME

3-92  2009 Sportster Service: Engine

19

20

6

17

9

10

14

1

15

2

18

16

7

8

4

3

11

5

12

13

13

sm03407

11.

1.

Nut

Rear exhaust cam gear

2.

12.

Rear intake cam gear

Oil pump drive gear

13.

3.

Cam gear bushing (4) (XL models only)

Front intake cam gear

4.

14.

Front exhaust cam gear

Rear exhaust cam gear bushing (XL models only)

15.

5.

Rear intake cam gear bushing (XL models only)

Pinion gear

6.

16.

Screw (11)

Pinion shaft bushing (XL models only)

17.

7.

Gearcase cover

Front intake cam gear bushing (XL models only)

8.

18.

Front exhaust cam gear bushing (XL models only)

T-key

19.

9.

Cover plate

Gearcase cover gasket

10.

20.

Right crankcase

Screw (2)

Figure 3-106. Gearcase and Valve Train Components (XL model shown)

1.

See 

Figure 3-106

. Bushings (7, 8, 13, 14, 15, 16) are press

fit in gearcase cover and crankcase. Inspect each bushing
against its corresponding cam gear shaft or pinion gear
shaft. Refer to 

Table 3-31

 for clearances and service wear

limits.

2.

See 

Figure 3-107

. Use BUSHING AND BEARING

PULLER (Part No. HD-95760-69A) to remove bushings
from gearcase cover and crankcase.

HOME

2009 Sportster Service: Engine  3-93

sm01480

Figure 3-107. Removing Cam Bushing from Gearcase

Cover

BUSHING INSTALLATION: XL ONLY

NOTE

Installing and reaming crankcase and gearcase cover bushings
may alter the center distances between mating gears and may
result in an increase in gear noise. For quiet-running gears,
the gears should be matched to the center distances.

Cam Gear Bushings in Right Crankcase

See 

Figure 3-108

. Each cam gear bushing, to be installed in

right crankcase, must be positioned in crankcase bore with its
oiling slot at exact top of bore (12 o'clock position).

1.

Using an arbor press, install each bushing in its crankcase
bore so that bushing shoulder contacts crankcase boss.

2.

After you install a new bushing in right crankcase, ream
the bushing to correct size. See 

3.20 GEARCASE COVER

AND CAM GEARS, Bushing Reaming: XL Only

.

Table 3-31. Inspection

SERVICE WEAR

LIMIT

CORRECT CLEARANCE

GEAR

SHAFT

MM

IN.

MM

IN.

0.08

0.003

0.018-0.056

0.0007-0.0022

Cam

0.13

0.005

0.058-0.109

0.0023-0.0043

Pinion

1

2

3

sm01481

1.

Cam gear bushing

2.

Slot at top

3.

Right crankcase

Figure 3-108. Cam Gear Bushing Installed in Crankcase

Cam Gear Bushings (Except Rear Intake
Bushing) in Gearcase Cover

1.

See 

Figure 3-106

. Using an arbor press, install each

bushing (7, 8, and 14) in its gearcase cover (17) bore so
that bushing shoulder contacts cover boss. There is no
need to orient these particular bushings in any specific
position of rotation within gearcase cover bores.

2.

After you install a new bushing in gearcase cover, line-
ream the bushing to correct size. See 

3.20 GEARCASE

COVER AND CAM GEARS, Bushing Reaming: XL Only

.

Rear Intake Cam Gear Bushing in Gearcase
Cover

See 

Figure 3-106

. Rear intake cam gear bushing (15) must be

installed in its gearcase cover (17) bore using an arbor press.
You will need to orient the bushing in a specific position of
rotation within the cover bore.

1.

See 

Figure 3-109

. Position bushing (1) over bore of gear-

case cover (2) with chamfered edge downward and slot
upward. Align slot in bushing with slot in gearcase cover
boss. Press bushing into cover bore until bushing is flush
with cover boss.

2.

After you install the new bushing in the gearcase cover,
line-ream the bushing to the correct size. See

3.20 GEARCASE COVER AND CAM GEARS, Bushing
Reaming: XL Only

.

Pinion Shaft Bushing in Gearcase Cover

1.

See 

Figure 3-106

. Using an arbor press, install pinion shaft

bushing (16) in gearcase cover (17) so that bushing is
flush with cover boss. There is no need to orient this par-
ticular bushing in any specific position of rotation within
the gearcase cover bore.

2.

See 

Figure 3-110

. Although the original pinion shaft

bushing is not "pinned," the replacement bushing must be
secured from possible rotation within the cover bore, by
installation of a dowel pin. Drill a No. 31 hole, 0.281 in.
(7.14 mm) deep, at top side of boss (side toward top of
gearcase cover), centering the drill bit on the cover bore

HOME

3-94  2009 Sportster Service: Engine

circle (hole is drilled half in bushing O.D. and half in cover
bore I.D.).

3.

Drive a new dowel pin no more than 0.20 in. (5.1 mm)
below the bushing face. Carefully peen edges of hole to
lock the pin in place.

4.

After you install a new bushing in gearcase cover, line-
ream the bushing to the correct size. See 

3.20 GEAR-

CASE COVER AND CAM GEARS, Bushing Reaming: XL
Only

.

4

1

2

3

sm01482

1.

Rear intake cam gear bushing

2.

Gearcase cover

3.

Cam bushing slot

4.

Gearcase cover slot

Figure 3-109. Rear Intake Cam Gear Bushing Installed in

Gearcase Cover

sm01483

Figure 3-110. Drilling Pinion Bushing Dowel Pin Hole in

Gearcase Cover

BUSHING REAMING: XL ONLY

TOOL NAME

PART NUMBER

CAMSHAFT BUSHING REAMER
PILOT

HD-38871

REAR INTAKE CAM GEAR BUSHING
REAMER

HD-94803-67

PINION SHAFT BUSHING REAMER

HD-94812-1

PINION SHAFT BUSHING REAMER

HD-94812-87

NOTES

•

Installing and reaming crankcase and gearcase cover
bushings may alter the center distances between mating
gears and may result in an increase in gear noise. For
quiet-running gears, the gears should be matched to the
center distances.

•

Bushings in right crankcase serve as pilots for reaming
gearcase cover bushings and must, therefore, be reamed
to size first.

•

After reaming any bushing, check shaft fit in the bushing.
It may be necessary to make a second pass with reamer
to attain proper fit.

Cam Gear Bushings in Right Crankcase

1.

Separate two halves of crankcase, if not already done.
Place right crankcase on flat surface with gearcase side
up.

2.

See 

Figure 3-111

. Position CAMSHAFT BUSHING

REAMER PILOT (Part No. HD-38871) onto gearcase side
of crankcase; upper right and lower left indexing holes in
pilot must be placed over dowels in crankcase. Insert two
bolts (supplied with pilot) through two remaining holes in
pilot, and into threaded holes of crankcase. Tighten bolts
securely.

3.

Insert a standard 11/16-in. diameter reamer through pilot
hole and into bushing while turning reamer clockwise.
Continue turning reamer clockwise through bushing until
smooth shank of reamer passes through hole in pilot.

4.

Detach reamer from handle. Pull reamer out opposite side
of crankcase.

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)

5.

Thoroughly clean right crankcase, removing all metal
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.

HOME

2009 Sportster Service: Engine  3-95

3

2

1

sm01484

1.

Camshaft bushing reamer pilot (Part No. HD-
38871)

2.

Standard 11/16-in. reamer

3.

Reamer handle

Figure 3-111. Reaming Cam Gear Bushing in Right

Crankcase

Cam Gear Bushings (Except Rear Intake
Bushing) in Gearcase Cover

NOTE

Newly installed cam gear bushings in the gearcase cover must
be line reamed, using the right crankcase as a pilot for the
reamer, to establish correct clearance and to ensure perfect
alignment. If crankcase halves are not separated on your
motorcycle, use a spare right crankcase to perform the following
line reaming procedures.

1.

See 

Figure 3-106

. Bushings (7, 8 and 14) to be reamed

must be installed in gearcase cover (17) as described in

3.20 GEARCASE COVER AND CAM GEARS, Bushing
Installation: XL Only

. Attach gearcase cover to right

crankcase (10), which has been disassembled from left
crankcase, securing with a minimum of three mounting
screws.

2.

Insert a standard 11/16-in. diameter reamer through the
previously reamed cam gear bushing (13) in right crank-
case, which is in line with one of the bushings to be
reamed in gearcase cover.

3.

Turn reamer clockwise through bushing in cover until
reamer bottoms.Then give reamer one complete clockwise
turn to size the bushing. Continue turning reamer clockwise
while extracting reamer from bushing.

4.

Repeat two previous steps for remaining two cam gear
bushings (except rear intake bushing) in gearcase cover,
if required.

5.

Separate gearcase cover from right crankcase. Inspect
bushings for proper cam gear shaft fit. Repeat line reaming
operation if necessary.

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)

6.

Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.

Rear Intake Cam Gear Bushing in Gearcase
Cover

NOTE

A newly installed rear intake cam gear bushing in the gearcase
cover must be line reamed, using the right crankcase as a pilot
for the reamer, to establish correct clearance and to ensure
perfect alignment. If crankcase halves are not separated on
your motorcycle, use a spare right crankcase to perform the
following line reaming procedures.

1.

See 

Figure 3-106

. Rear intake cam gear bushing (15)

must be installed in gearcase cover (17) as described in

3.20 GEARCASE COVER AND CAM GEARS, Bushing
Installation: XL Only

.

2.

Identify the previously reamed rear intake cam gear
bushing (13) in right crankcase (10), which has been dis-
assembled from left crankcase. Insert the shank end of
REAR INTAKE CAM GEAR BUSHING REAMER (Part
No. HD-94803-67) through gearcase side of this bushing.

3.

With reamer inserted into bushing in right crankcase,
attach gearcase cover to right crankcase, securing with a
minimum of three mounting screws.

4.

Turn reamer clockwise through bushing in gearcase cover
until reamer bottoms. Then give reamer one complete
clockwise turn to size the bushing. Continue turning reamer
clockwise while extracting reamer from bushing.

5.

Separate gearcase cover from right crankcase. Inspect
bushing for proper cam gear shaft fit. Repeat line reaming
operation if necessary.

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)

6.

Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.

Pinion Shaft Bushing in Gearcase Cover

NOTE

A newly installed pinion shaft bushing in the gearcase cover
must be line reamed, using both the right crankcase and
PINION SHAFT BUSHING REAMER (Part No. HD-94812-87)
as pilots for the reamer, to establish correct clearance and to
ensure proper alignment. If crankcase halves are not separated

HOME

3-96  2009 Sportster Service: Engine

on your motorcycle, use a spare right crankcase to perform
the following line reaming procedure.

1.

See 

Figure 3-106

. Pinion shaft bushing (16) must be

installed in gearcase cover (17) as described in

3.20 GEARCASE COVER AND CAM GEARS, Bushing
Installation: XL Only

. Attach gearcase cover to right

crankcase (10), which has been disassembled from left
crankcase, securing with a minimum of three mounting
screws.

2.

See 

Figure 3-112

. Install PINION SHAFT BUSHING

REAMER PILOT (Part No. HD-94812-87) into right
crankcase roller race. Insert PINION SHAFT BUSHING
REAMER (Part No. HD-94812-1) through the pilot.

3.

Turn reamer clockwise through bushing in gearcase cover
until reamer bottoms. Then give reamer one complete
clockwise turn to size the bushing. Continue turning reamer
clockwise while extracting reamer from bushing.

4.

Separate gearcase cover from right crankcase. Inspect
bushing for proper pinion shaft fit. Repeat line reaming
operation if necessary.

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)

5.

Remove pilot from right crankcase roller race. Thoroughly
clean gearcase cover, removing all metal chips/shavings.

Blow out all bushing bores and oil passages using low
pressure compressed air.

sm01485

Figure 3-112. Line Reaming Pinion Shaft Bushing

ASSEMBLY AND INSTALLATION

See 

3.18 BOTTOM END OVERHAUL: ASSEMBLY, Cam Gears

and Gearcase Cover: XL Models

 or 

3.18 BOTTOM END

OVERHAUL: ASSEMBLY, Cam Gears and Gearcase Cover:
XR Models

 to install cam gears and gearcase cover in engine.

HOME

2009 Sportster Service: Engine  3-97

3.21

CYLINDER HEAD

REMOVAL

See 

3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder

Heads

 to remove cylinder head from engine.

DISASSEMBLY

TOOL NAME

PART NUMBER

VALVE SPRING COMPRESSOR

HD-34736-B

1.

See 

Figure 3-113

. Remove two screws (17), lock washers

(18) and stabilizer link bracket (16) from front head.

2.

See 

Figure 3-114

. Clamp VALVE SPRING COM-

PRESSOR (Part No. HD-34736-B) in vice and compress
valve spring (item 5, 

Figure 3-113

).

HOME

3-98  2009 Sportster Service: Engine

14

15

3

4

5

6

16

7

1

2

18

17

13

9

10

11

12

8

sm01504

10.

1.

Cylinder head gasket

Head bolt, short (2)

2.

11.

Head bolt, long (2)

Valve (1) intake, (1) exhaust

12.

3.

Valve seat (2)

Valve collar retainer (4)

4.

13.

Upper valve spring collar (2)

Cylinder head bracket*

14.

5.

Screw (2)*

Valve spring (2)

6.

15.

Valve seal and lower valve spring collar assembly
(2)

Washer (2)*

16. Stabilizer link bracket (front cylinder head only)

7.

17.

Valve guide, intake and exhaust (2)

Screw (2)

18.

8.

Lock washer (2)

Cylinder head

9.

Exhaust port stud (2)

Figure 3-113. Cylinder Head Assembly (typical) (* Vehicles with Side Mounted Horn Only)

HOME

2009 Sportster Service: Engine  3-99

sm01511

Figure 3-114. Compressing Valve Springs (Valve Spring

Compressor, Part No. HD-34376-B)

3.

See 

Figure 3-113

. Remove valve collar retainers (3), upper

valve spring collar (4) and valve spring (5). Mark valve
collar retainers for reassembly in original positions.

4.

Use a fine tooth file to remove any burrs on the valve stem
at the retainer groove. Mark valve to ensure that it will be
reassembled in the same head.

5.

Remove valve (11), and valve seal and lower valve spring
collar assembly (6) by hand. No special tools are required
to remove valve seal and lower valve spring collar
assembly.

6.

Repeat above procedure for other valve. Then disas-
semble other head following same procedure.

CLEANING AND INSPECTION

TOOL NAME

PART NUMBER

VALVE GUIDE HONE

B-45525

VALVE GUIDE CLEANING BRUSH

HD-34751

VALVE SPRING TESTER

HD-96796-47

Cylinder Heads

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)

1.

Bead blast or scrape carbon from head and valve ports.
Be careful to avoid scratching or nicking cylinder head-to-
cylinder joint faces. Blow off loosened carbon or dirt with
compressed air.

2.

Soak cylinder head in an aluminum-compatible
cleaner/solvent to loosen carbon deposits.

3.

Wash all parts in non-flammable solvent, followed by a
thorough washing with hot, soapy water. Blow out oil
passages in head. Be sure they are free of sludge and
carbon particles. Remove loosened carbon from valve
head and valve stem using a wire wheel. Never use a file
or other hardened tool which could scratch or nick valve.
Polish valve stem with very fine emery cloth or steel wool.

4.

See 

Figure 3-115

. Check head gasket surface on head

for flatness. Machine or replace any head which exceeds
SERVICE WEAR LIMIT of 0.006 in. (0.152 mm).

sm01512

Figure 3-115. Checking Gasket Surface: Must Be Flat

Within 0.006 in. (0.152 mm)

Rocker Arm Assemblies

1.

Check each rocker arm at pad end and push rod end for
uneven wear or pitting. Replace rocker arm if either condi-
tion exists.

NOTE

Most of the wear in rocker arm shafts and bores results from
the up and down movement of the pushrods and valves.
Therefore, the following measurements should be taken top-
to-bottom on rocker arm shafts and bores.

2.

See 

Figure 3-116

. Measure and record rocker arm shaft

diameter at the positions where rocker arm bushings ride
and where shaft fits in inner rocker cover.

HOME

3-100  2009 Sportster Service: Engine

sm01514

Figure 3-116. Measuring Rocker Arm Shaft Diameter at

Bushing Position (top) and Cover Position (bottom)

3.

Measure and record rocker arm shaft bore diameters.

a.

See 

Figure 3-117

. Measure rocker arm shaft bore in

inner rocker cover.

b.

See 

Figure 3-118

. Measure rocker arm bushing inner

diameter.

4.

Check clearances and measurements obtained in step 3
against specifications in 

3.2 SPECIFICATIONS

. Repair

or replace parts exceeding Service Wear Limits. If rocker
arm bushings require replacement, see 

3.21 CYLINDER

HEAD, Replacing Rocker Arm Bushings

.

5.

See 

Figure 3-119

. Assemble rocker arms and rocker arm

shafts into inner rocker cover.

6.

Check end play of rocker arm with feeler gauge. Replace
rocker arm or inner rocker cover or both if end play
exceeds 0.025 in. (0.635 mm).

sm01515

Figure 3-117. Measuring Rocker Arm Shaft Bore Diameter

in Inner Rocker Cover

sm01516

Figure 3-118. Measuring Rocker Arm Bushing Inner

Diameter

HOME

2009 Sportster Service: Engine  3-101

3

2

1

sm01518

1.

Inner rocker cover

2.

Rocker arm shaft (2)

3.

Rocker arm (2)

Figure 3-119. Assembling Inner Rocker Cover (typical; XL

shown)

Valves

1.

Replace the valve if there is evidence of burning or
cracking.

2.

Inspect the end of the valve stem for pitting or uneven
wear. Replace the valve if either of these conditions exist.

3.

Inspect for burrs around the valve stem retainer groove.
Remove burrs with a fine tooth file if found.

4.

Valve heads should have a seating surface width of 0.040-
0.062 in. (1.02-1.57 mm), and should be free of pit marks
and burn spots. The color of carbon on exhaust valves
should be black or dark brown. White or light buff carbon
indicates excessive heat and burning.

Valve Seats

NOTE

Valve seats are subject to wear, pitting, and burning. Resurface
valve seats whenever valves are refinished.

1.

Inspect valve seats for cracking, chipping or burning.
Replace valve seats if any evidence of these conditions
exists.

sm01519

Figure 3-120. Measuring Valve Stem Protrusion

2.

See 

Figure 3-120

. Check valve seats for recession by

measuring valve stem protrusion.

a.

Wipe valve seats and valve faces clean. Insert valve
into valve guide.

b.

Measure valve stem protrusion from end of valve stem
to machined surface of head upon which the lower
valve collar sits, as shown. If valve stem protrudes
more than 2.082 in. (52.883 mm), replace valve seat
or cylinder head.

NOTE

Replacing a valve seat is a complex operation requiring special
equipment. If the valve seat is loose or is not fully seated in
the head, seat movement will prevent the proper transfer of
heat from the valve. The valve seat surface must be flush with
(or below) the head surface. See 

3.2 SPECIFICATIONS

 for

valve seat-to-cylinder head fit.

Valve Guides

1.

Clean valve guides by lightly honing with VALVE GUIDE
HONE (Part No. B-45525).

2.

Scrub valve guides with VALVE GUIDE CLEANING
BRUSH (Part No. HD-34751) and hot soapy water.
Measure valve stem outer diameter and valve guide inner
diameter. Check measurements against See 

3.2 SPE-

CIFICATIONS

.

Valve Springs

1.

Inspect valve springs for broken or discolored coils.

NOTE

A single valve spring is used for each valve. The inner and
outer springs are combined into one progressively wound,
tapered spring.

2.

See 

Figure 3-121

. Check free length of each spring with

caliper as shown. Test compression force of spring using

HOME

3-102  2009 Sportster Service: Engine

6.

Remove o-ring (26) from filter housing mount (19).

Fuel Pump Assembly and Pump Bracket

1.

See 

Figure 4-81

. Make note of the location of any cable

straps securing wiring harness to the fuel pump bracket
(3). Cut and discard cable straps.

2.

See 

Figure 4-82

. Unplug fuel pump harness connector

[86] (13).

3.

Unplug low fuel level sensor connector from fuel
pump/sender harness (14).

4.

Remove and discard clamp (1). Remove filter housing
hose (11) from top of fuel pump (2).

5.

Remove and discard pump assembly clamp (7). Remove
pump assembly with pump insulator (3) from pump bracket
(5).

6.

Remove push nut (16) and low fuel level sensor assembly
(17) from pump bracket.

7.

Remove three screws w/lock washers (6) and remove
pump bracket from cover plate (9).

Low Fuel Level Sensor Assembly

1.

See 

Figure 4-81

. Make note of the location of cable strap

(1) securing low fuel level sensor connector to filter
housing hose (4). Cut and discard cable strap.

2.

See 

Figure 4-82

. Unplug low fuel level sensor connector

(15) from fuel pump/sender harness (14).

3.

Remove push nut (16) and low fuel level sensor assembly
(17) from pump bracket (5).

Fuel Pump/Sender Harness

1.

See 

Figure 4-81

. Make note of the location of cable straps

(1) securing fuel pump/sender harness to fuel pump
bracket (3) and filter housing hose (4). Cut and discard
cable straps.

2.

See 

Figure 4-82

. Unplug low fuel level sensor connector

(15) from fuel pump/sender harness (14). Unplug fuel
pump harness connector [86] (13) from fuel pump.

3.

Remove screw w/lock washer (6) securing fuel
pump/sender harness grounding eyelet to pump bracket
(5).

4.

Remove retaining ring (18). Remove fuel pump/sender
harness from cover plate (9).

ASSEMBLY

The assembly procedure is broken down into the following
groups:

•

Fuel pump/sender harness.

•

Low fuel level sensor assembly.

•

Fuel pump assembly and pump bracket.

•

Pressure regulator and filter housing.

Fuel Pump/Sender Harness

1.

See 

Figure 4-82

. Install fuel pump/sender harness (14)

into cover plate (9). Secure with retaining ring (18).

2.

Secure fuel pump/sender harness grounding eyelet to
pump bracket (5) using screw w/lock washer (6). Tighten
to 19-36 in-lbs (2.1-4.1 Nm).

3.

Plug low fuel level sensor connector (15) into fuel
pump/sender harness. Plug fuel pump harness connector
[86] (13) into fuel pump (2).

4.

See 

Figure 4-81

. Secure wiring harness to fuel pump

bracket (3) and filter housing hose (4) with cable straps
(1).

Low Fuel Level Sensor Assembly

1.

See 

Figure 4-82

. Install low fuel level sensor assembly

(17) onto pump bracket (5). Secure with push nut (16).

2.

Plug low fuel level sensor connector (15) into fuel
pump/sender harness (14).

3.

See 

Figure 4-81

. Secure low fuel level sensor connector

and fuel pump/sender harness to filter housing hose (4)
with cable strap (1).

Fuel Pump Assembly and Pump Bracket

1.

See 

Figure 4-82

. Install pump bracket (5) onto cover plate

(9). Secure with three screws w/lock washers (6). Tighten
to 19-36 in-lbs (2.1-4.1 Nm).

2.

Install low fuel level sensor assembly (17) onto pump
bracket. Secure with push nut (16).

3.

Install fuel pump assembly (2) with pump insulator (3) onto
pump bracket. Secure with pump assembly clamp (7) (for
relative position of clamp, see 

Figure 4-81

.)

4.

Install filter housing hose (11) on top of fuel pump. Secure
with clamp (1).

5.

Plug in fuel pump harness connector [86] (13).

6.

See 

Figure 4-81

. Secure fuel pump/sender harness to fuel

pump bracket (3) with cable straps (1).

Pressure Regulator and Filter Housing

1.

See 

Figure 4-82

. Examine o-ring (26) for cuts, tears,

cracking or other damage. Replace with new o-ring if
necessary (only available as part of filter kit). Install o-ring
onto filter housing mount (19).

2.

Install fuel filter element (25) into filter housing (23). Install
filter housing onto filter housing mount. Secure with
retaining clip (24) at bottom of housing, making sure that
clip is oriented exactly as shown in 

Figure 4-82

.

3.

Install pressure regulator (22) on top of filter housing.
Secure with second retaining clip (24), making sure that
clip is oriented exactly as shown in 

Figure 4-82

.

4.

Install filter housing hose (11) on top of fuel pump (2).
Secure with clamp (1).

5.

Install ground clip (12) on top of filter housing.

6.

See 

Figure 4-81

. Secure fuel pump/sender harness to

filter housing hose (4) with cable strap (1).

HOME

2009 Sportster Service: Fuel System  4-59

22

23

11

25

26

14

13

15

16

17

18

19

20

21

14

10

9

8

7

6

5

4

3

2

1

12

24

sm01611

14.

1.

Fuel pump/sender harness

Clamp

2.

15.

Fuel pump

Low fuel level sensor connector

16.

3.

Push nut

Pump insulator

4.

17.

Cover plate seal

Low fuel level sensor

18.

5.

Retaining ring

Pump bracket

6.

19.

Screw w/ lock washer (3)

Filter housing mount

20.

7.

Screw (5)

Pump assembly clamp

8.

21.

Inlet sock

Fuel outlet quick-connect fitting

22.

9.

Pressure regulator

Cover plate

10.

23.

Fuel pump/sender harness connector [141]

Filter housing

24.

11.

Retaining clip (2)

Filter housing hose

12.

25.

Ground clip

Fuel filter element

26.

13.

O-ring

Fuel pump harness connector [86]

Figure 4-82. Fuel Pump and Sender Assembly

INSTALLATION

1.

See 

Figure 4-82

. Install new cover plate seal (4) into

groove in cover plate (9).

2.

Carefully install fuel pump module into fuel tank. See

Figure 4-80

. To facilitate installation, tilt module as you

begin to lower it into fuel tank, as shown in the photo. Then
straighten module to complete installation.

3.

See 

Figure 4-79

. Install five screws (3). Tighten to 40-45

in-lbs (4.5-5.1 Nm).

4.

Install fuel tank on vehicle. See 

4.6 FUEL TANK: XL

MODELS

 or 

4.7 FUEL TANK: XR MODELS

.

a.

Make sure fuel pump harness fits in wire harness
caddy latch clip with loop in harness between latch
clip and fuel pump module to avoid harness being
pinched between fuel tank and frame backbone.

b.

Plug in fuel pump harness connector [141].

c.

Connect vent hose to fuel tank vent nipple.

5.

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

4.6 FUEL

TANK: XL MODELS

 or 

4.7 FUEL TANK: XR MODELS

.

6.

Install main fuse. Close left side cover. See 

6.38 MAIN

FUSE

.

HOME

4-60  2009 Sportster Service: Fuel System