2009 Harley Davidson Sportster Service Manual – PDF DOWNLOAD
Part Number 99484-09
DESCRIPTION:
2009 Harley Davidson Sportster Service Manual – PDF DOWNLOAD
ABOUT THIS MANUAL
GENERAL:
- This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair.
- Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Drive/Transmission
6 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Compensating Sprocket
E Appendix E Glossary
Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation. For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS. For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
TABLE OF CONTENTS:
2009 Harley Davidson Sportster Service Manual – PDF DOWNLOAD
MAINTENANCE
1 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 1-1
1 2 GENERAL
Servicing a New Motorcycle 1-4
Safe Operating Maintenance 1-4
Shop Practices 1-4
Repair Notes 1-4
Safety 1-4
Removing Parts 1-4
Cleaning 1-4
Disassembly and Assembly 1-5
Checking Torques on Fasteners 1-5
Magnetic Parts Trays 1-5
Repair and Replacement Procedures 1-5
Hardware and Threaded Parts 1-5
Threadlocking Agents 1-5
Wiring, Hoses and Lines 1-5
Instruments and Gauges 1-5
Bearings 1-5
Bushings 1-5
Gaskets 1-5
Lip Type Seals 1-5
O-Rings (Preformed Packings) 1-6
Gears 1-6
Shafts 1-6
Part Replacement 1-6
Exhaust System Leakage 1-6
Cleaning 1-6
Part Protection 1-6
Cleaning Process 1-6
Rust or Corrosion Removal 1-6
Bearings 1-6
Tool Safety 1-6
Air Tools 1-6
Wrenches 1-6
Pliers/Cutters/Pry bars 1-6
Hammers 1-7
Punches/Chisels 1-7
Screwdrivers 1-7
Ratchets and Handles 1-7
Sockets 1-7
Storage Units 1-7
1 3 FUEL AND OIL
Fuel 1-8
Gasoline Blends 1-8
Engine Lubrication 1-8
Winter Lubrication 1-9
1 4 MAINTENANCE SCHEDULE
General 1-10
1 5 BULB REQUIREMENTS
Bulb Chart 1-14
1 6 ENGINE OIL AND FILTER
Checking and Adding Oil 1-15
Removing and Replacing Oil Filler Cap 1-15
Checking Oil with Cold Engine 1-15
Checking Oil with Warm Engine 1-15
Changing Oil and Filter 1-16
General 1-16
Draining Oil Tank 1-16
Removing Oil Filter 1-16
Installing New Oil Filter 1-17
Refilling Oil Tank 1-17
1 7 BRAKES
General 1-18
Inspection 1-18
Troubleshooting 1-18
1 8 BLEEDING HYDRAULIC BRAKE SYSTEM
General 1-20
Bleeding Front Brake: All Models 1-20
Bleeding Rear Brake: All Models 1-22
1 9 BRAKE PADS AND DISCS: XL MODELS
Inspection 1-24
Brake Pads 1-24
Brake Disc Thickness, Lateral Runout and
Warpage 1-24
Brake Pad Replacement: Front 1-25
Brake Pad Replacement: Rear 1-27
1 10 BRAKE PADS AND DISCS: XR MODELS
Inspection 1-31
Brake Pads 1-31
Brake Disc Thickness, Lateral Runout and
Warpage 1-31
Brake Pad Replacement: Front 1-31
Removal 1-31
Installation 1-32
Brake Pad Replacement: Rear 1-33
Removal 1-33
Installation 1-34
1 11 TIRES AND WHEELS
Tires 1-36
Tire Replacement 1-37
Inspection 1-37
When To Replace Tires 1-37
Wheel Bearings 1-37
Wheel Spokes 1-37
1 12 PRIMARY CHAIN
Inspection 1-39
Adjustment 1-39
1 13 CLUTCH
Adjustment 1-41
1 14 TRANSMISSION LUBRICANT
Transmission Lubrication: Sportster Models 1-43
Check Lubricant Level 1-43
Changing Lubricant 1-44
1 15 REAR BELT AND SPROCKETS
General 1-45
Cleaning 1-45
Inspection 1-45
Sprockets 1-45
Idler Pulley: XR Models 1-45
Rear Belt 1-45
1 16 REAR BELT DEFLECTION
Rear Drive Belt: Sportster Models 1-47
III
TABLE OF CONTENTS
General 1-47
Gauging Deflection 1-47
Belt Deflection Adjustment 1-48
Wheel Alignment 1-49
Checking Wheel Alignment 1-49
Adjusting Wheel Alignment 1-50
1 17 BATTERY MAINTENANCE
General 1-52
Battery Disconnection and Removal 1-53
Cleaning and Inspection 1-54
Charging Battery 1-54
Safety Precautions 1-54
Using a Battery Charger 1-54
Battery Installation and Connection 1-55
Storage 1-56
1 18 SPARK PLUGS
General 1-58
Inspection 1-58
Spark Plug Cable Inspection 1-59
1 19 STEERING HEAD BEARINGS
Adjustment 1-60
Lubrication 1-60
1 20 SHOCK ABSORBER ADJUSTMENT
Shock Absorber Preload Adjustment: Sportster Models 1-62
1 21 REAR FORK BEARINGS
Lubrication 1-64
Replacement 1-64
1 22 FRONT FORK OIL
Changing Fork Oil: XL Models 1-65
Draining Fork Oil 1-65
Filling Fork Oil: Forks Assembled, in Frame 1-65
Filling Fork Oil: Forks Disassembled, out of Frame 1-66
Changing Fork Oil: XR Models 1-66
Left Fork 1-67
Right Fork 1-69
1 23 CABLE AND CHASSIS LUBRICATION
General 1-72
Cables and Hand Levers 1-72
Foot Shift Lever and Rear Brake Pedal 1-72
Jiffy Stand 1-72
Steering Head Bearings 1-72
1 24 AIR CLEANER: XL MODELS
General 1-73
Removal 1-73
Cleaning, Inspection and Repair 1-73
Installation 1-74
1 25 AIR CLEANER: XR MODELS
General 1-75
Removal 1-75
Cleaning, Inspection and Repair 1-76
Installation 1-76
1 26 EXHAUST SYSTEM
Exhaust System Leak Check 1-78
1 27 THROTTLE CONTROL
Cable Inspection and Lubrication 1-79
Cable Adjustment 1-79
1 28 IDLE SPEED AND IGNITION TIMING
Idle Speed 1-80
Ignition Timing 1-80
1 29 FUEL SUPPLY FILTER
General 1-81
Removal 1-81
Installation 1-81
1 30 ENGINE MOUNTS AND STABILIZER
LINKS
Inspection 1-82
1 31 HEADLAMP ALIGNMENT
Headlamp Alignment 1-83
Headlamp Adjustment: Sportster Models 1-83
Adjustment (XL 883C and XL 1200C Models) 1-83
Adjustment (All Models Except XL 883C and XL
1200C) 1-84
1 32 FLUID AND LUBRICANT
REQUIREMENTS
Brake Fluid 1-85
Brake Component Grease 1-85
Front Fork Oil 1-85
Primary Drive/Transmission Lubricant 1-85
Engine Oil 1-85
1 33 CRITICAL FASTENERS
Inspection 1-86
Checking Torques on Fasteners 1-86
1 34 STORAGE
General 1-88
Placing in Storage 1-88
Removal From Storage 1-88
1 35 TROUBLESHOOTING
General 1-90
Engine 1-90
Starter Motor Does Not Operate or Does Not Turn Engine
Over 1-90
Engine Turns Over But Does Not Start 1-90
Starts Hard 1-90
Starts But Runs Irregularly or Misses 1-90
Spark Plug Fouls Repeatedly 1-91
Pre-Ignition or Detonation (Knocks or Pings) 1-91
Check Engine Light Illuminates During Operation 1-91
Overheating 1-91
Valve Train Noise 1-91
Excessive Vibration 1-91
Lubrication System 1-91
Oil Does Not Return To Oil Tank 1-91
IV TABLE OF CONTENTS
TABLE OF CONTENTS
Engine Uses Too Much Oil Or Smokes Excessively 1-91
Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc 1-91
Low Oil Pressure 1-91
High Oil Pressure 1-92
Electrical System 1-92
Alternator Does Not Charge 1-92
Alternator Charge Rate Is Below Normal 1-92
Speedometer Operates Erratically 1-92
Transmission 1-92
Shifts Hard 1-92
Jumps Out Of Gear 1-92
Clutch Slips 1-92
Clutch Drags Or Does Not Release 1-92
Clutch Chatters 1-92
Handling 1-92
Brakes 1-92
Brake Does Not Hold Normally 1-92
CHASSIS
2 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 2-1
2 2 SPECIFICATIONS
Sportster Specifications 2-8
Chassis Specifications 2-8
Tire Specifications 2-9
2 3 VEHICLE IDENTIFICATION NUMBER
(V I N )
Vehicle Identification Number (V I N ): Sportster Models 2-11
General 2-11
Abbreviated V I N 2-11
2 4 WHEELS
General 2-13
Troubleshooting 2-13
Front Wheel 2-14
Removal 2-14
Disassembly: Cast Front Wheel 2-15
Disassembly: Laced Front Wheel 2-15
Cleaning and Inspection 2-15
Assembly: Cast Front Wheel 2-15
Assembly: Laced Front Wheel 2-16
Installation 2-20
Rear Wheel 2-20
Removal 2-20
Disassembly 2-21
Cleaning and Inspection 2-21
Assembly 2-21
Installation 2-24
Sealed Wheel Bearings 2-24
Inspection 2-24
Removal 2-25
Installation 2-27
2 5 WHEEL LACING: 16 INCH RIM
General 2-28
Procedure 2-28
2 6 WHEEL LACING: 19 INCH RIM
Procedure 2-31
2 7 WHEEL LACING: 21 INCH RIM
General 2-35
Procedure 2-35
2 8 TRUING LACED WHEELS
General 2-39
Lateral Truing 2-39
Radial Truing 2-40
2 9 CHECKING CAST WHEEL RUNOUT
General 2-42
Lateral Runout 2-42
Radial Runout 2-42
2 10 FRONT BRAKE MASTER CYLINDER
General 2-43
Inspection 2-43
Removal 2-43
Disassembly 2-45
Cleaning, Inspection and Repair 2-47
Assembly 2-47
Installation 2-48
2 11 FRONT BRAKE CALIPER: XL MODELS
Removal 2-52
Disassembly 2-53
Cleaning, Inspection and Repair 2-55
Assembly 2-56
Lubricating Front Caliper Bolt Pins and Boots 2-56
Installing Brake Pads in Caliper 2-57
Installation 2-58
2 12 FRONT BRAKE CALIPER: XR MODELS
Removal 2-60
Disassembly 2-61
Cleaning, Inspection and Repair 2-62
Assembly 2-63
Installation 2-64
2 13 REAR BRAKE MASTER CYLINDER: XL
MODELS
General 2-65
Inspection 2-65
Removal 2-65
Disassembly 2-68
Cleaning, Inspection and Repair 2-69
Assembly 2-70
Installation 2-72
2 14 REAR BRAKE MASTER CYLINDER: XR
MODELS
General 2-73
Inspection 2-73
Removal 2-73
Disassembly 2-74
Cleaning, Inspection and Repair 2-75
Assembly 2-76
TABLE OF CONTENTS V
TABLE OF CONTENTS
Installation 2-77
2 15 REAR BRAKE MASTER CYLINDER
RESERVOIR
General 2-79
Removal: XL Models 2-79
Installation: XL Models 2-80
Removal: XR Models 2-80
Installation: XR Models 2-81
2 16 REAR BRAKE CALIPER: XL MODELS
Removal 2-82
Disassembly 2-84
Cleaning, Inspection and Repair 2-85
Lubricating Rear Caliper Bolt Pins and Boots 2-85
Assembly 2-86
Installation 2-87
2 17 REAR BRAKE CALIPER: XR MODELS
Removal 2-90
Disassembly 2-91
Cleaning, Inspection and Repair 2-93
Assembly 2-93
Installation 2-94
2 18 BRAKE LINES
Front Brake Line: All Models 2-97
Removal 2-97
Installation 2-98
Rear Brake Line: XL Models 2-99
Removal 2-100
Installation 2-100
Rear Brake Line: XR Models 2-101
Removal 2-101
Installation 2-102
2 19 TIRES
General 2-103
Removal 2-103
Cleaning, Inspection and Repair 2-104
Installation 2-104
Tube Type Tires 2-104
Tubeless Tires 2-105
Checking Tire Runout 2-105
Lateral Runout 2-105
Radial Runout 2-105
Wheel Balancing 2-106
Weights for Laced Wheels 2-106
Weights for Cast Wheels 2-106
2 20 LEFT SIDE COVER
General 2-107
Opening Left Side Cover 2-107
Closing Left Side Cover 2-108
Removing Left Side Cover 2-108
Installing Left Side Cover 2-109
2 21 FRONT FORK: XL MODELS
General 2-110
Removal 2-110
Disassembly 2-110
Cleaning, Inspection and Repair 2-112
Assembly 2-112
Installation 2-113
2 22 FRONT FORK: XR MODELS
General 2-115
Removal 2-115
Disassembly 2-115
Left Side 2-115
Right Side 2-117
Cleaning and Inspection 2-119
Assembly 2-119
Left Side 2-119
Right Side 2-122
Installation 2-124
2 23 FORK STEM AND BRACKET
ASSEMBLY
Removal and Disassembly 2-126
Cleaning, Inspection and Repair 2-126
Assembly and Installation 2-127
2 24 BELT GUARD AND DEBRIS
DEFLECTOR
Belt Guard: XL Models 2-128
Removal 2-128
Installation 2-128
Debris Deflector: XL Models 2-128
Removal 2-128
Installation 2-128
Belt Guard: XR Models 2-128
Removal 2-128
Installation 2-128
Debris Deflector: XR Models 2-129
Removal 2-129
Installation 2-129
2 25 REAR FORK
General 2-130
Removal 2-130
Disassembly 2-130
Cleaning and Inspection 2-131
Assembly 2-131
Installation 2-131
2 26 SHOCK ABSORBERS
General 2-133
Removal 2-133
Cleaning and Inspection 2-133
Installation 2-133
2 27 STABILIZER LINKS
General 2-135
Upper Front Stabilizer Link 2-135
Removal 2-135
Installation 2-135
Lower Front Stabilizer Link 2-135
Removal 2-135
Installation 2-135
Rear Stabilizer Link 2-136
Removal 2-136
VI TABLE OF CONTENTS
TABLE OF CONTENTS
Installation 2-136
2 28 FRONT ENGINE MOUNT/ISOLATOR
Removal 2-137
Installation 2-138
2 29 REAR ENGINE MOUNT/ISOLATOR
Removal 2-139
Installation 2-141
2 30 THROTTLE CABLES: ALL MODELS
Removal and Disassembly 2-142
Cleaning, Inspection and Repair 2-144
Assembly and Installation 2-144
2 31 CLUTCH CONTROL
General 2-146
Removal and Disassembly 2-146
Clutch Cable: Lower 2-146
Clutch Lever and Clutch Cable: Upper 2-147
Clutch Hand Control 2-147
Assembly and Installation 2-148
Clutch Hand Control 2-148
Clutch Lever and Clutch Cable: Upper 2-149
Clutch Cable: Lower 2-149
Finish 2-149
2 32 HANDLEBARS
Removal 2-150
All Models 2-150
XL 883C and XL 1200C 2-150
All XL Models Except XL 883C, XL 1200C 2-151
XR1200 2-152
Installation 2-153
XL 883C and XL 1200C 2-153
All XL Models Except XL 883C, XL 1200C 2-154
XR1200 2-154
All Models 2-155
2 33 FRONT FENDER
XL Models 2-156
Removal 2-156
Installation 2-156
XR Models 2-156
Removal 2-156
Installation 2-156
2 34 REAR FENDER: ALL XL MODELS
EXCEPT XL 1200N
General 2-157
Removal 2-157
Installation 2-159
2 35 REAR FENDER AND LICENSE PLATE
BRACKET: XL 1200N
General 2-161
Removal and Disassembly 2-161
Assembly and Installation 2-163
2 36 REAR FENDER: XR MODELS
Removal 2-166
Installation 2-166
2 37 JIFFY STAND
General 2-167
Jiffy Stand Interlock: International Models 2-167
Removal 2-167
Cleaning and Lubrication 2-167
Installation 2-168
2 38 SEAT: XL MODELS
General 2-169
Seat Removal: XL Models 2-169
Seat Installation: XL Models 2-169
2 39 SEAT: XR MODELS
Seat Removal: XR 1200 Model 2-171
Seat Installation: XR 1200 Model 2-171
Passenger Pillion: XR 1200 Model 2-171
Removal 2-171
Installation 2-171
2 40 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS
Right Footrest and Rear Brake Pedal Assembly 2-173
Removal 2-173
Installation 2-173
Left Footrest and Shift Lever Assembly 2-173
Removal 2-173
Installation 2-173
2 41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS
Right Footrest and Rear Brake Pedal Assembly 2-175
Removal 2-175
Installation 2-175
Left Footrest and Shift Lever Assembly 2-176
Removal 2-176
Installation 2-177
Adjusting Shift Pedal 2-178
2 42 RIDER FOOT CONTROLS: XR MODELS
Right Footrest and Rear Brake Pedal Assembly 2-179
Removal 2-179
Installation 2-179
Left Footrest and Shift Lever Assembly 2-179
Removal 2-179
Installation 2-180
Adjusting Shift Pedal 2-180
2 43 PASSENGER FOOTRESTS
General 2-181
XL Models 2-181
Removal 2-181
Installation 2-181
XR Models 2-181
Removal 2-181
Installation 2-181
TABLE OF CONTENTS VII
TABLE OF CONTENTS
2 44 FORK LOCK
Removal 2-183
Installation 2-183
ENGINE
3 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 3-1
3 2 SPECIFICATIONS
Specifications: 2009 Sportster Models 3-5
3 3 ENGINE
General 3-11
3 4 OIL PRESSURE
General 3-12
Oil Pressure Indicator Lamp 3-12
Checking Oil Pressure 3-13
Connecting Gauge: XL Models 3-13
Connecting Gauge: XR Models 3-13
Testing Pressure 3-13
Removing Gauge: XL Models 3-13
Removing Gauge: XR Models 3-13
Finalize Test 3-13
3 5 CRANKCASE BREATHING SYSTEM: XL
MODELS
General 3-15
3 6 CRANKCASE BREATHING SYSTEM: XR
MODELS
General 3-16
3 7 TROUBLESHOOTING
Diagnosing Valve Train Noise 3-18
Compression Test 3-18
Cylinder Leakage Test 3-18
Diagnosing Smoking Engine or High Oil Consumption 3-19
Check Prior to Cylinder Head Removal 3-19
Check After Cylinder Head Removal 3-19
Adjustment and Testing 3-19
General 3-19
3 8 ENGINE LUBRICATION SYSTEM
Oil Pump Operation 3-20
Oil Flow: XL Models 3-23
Oil Flow: XR Models 3-23
3 9 HOW TO USE THIS SECTION
Typical Symptoms 3-29
Top End Repair 3-29
Bottom End Repair 3-29
3 10 TOP END SERVICE
Engine in Chassis 3-30
Engine Removed from Chassis 3-31
3 11 BOTTOM END SERVICE
Engine in Chassis 3-32
Engine Removed From Chassis 3-33
3 12 REMOVING ENGINE FROM CHASSIS
General 3-34
Procedure: XL Models 3-34
Procedure: XR Models 3-38
3 13 INSTALLING ENGINE IN CHASSIS
General 3-43
Procedure: XL Models 3-43
Procedure: XR Models 3-45
3 14 PRECISION COOLING SYSTEM: XR
MODELS
General 3-48
Return Oil Manifold 3-48
Removal 3-48
Installation 3-49
Cylinder Head Oil Return Lines 3-49
Removal 3-49
Installation 3-50
Cylinder Head Oil Feed Assembly 3-50
Removal 3-50
Installation 3-50
Oil Pump Lines 3-51
Removal 3-51
Installation 3-52
Oil Cooler 3-52
Removal 3-52
Installation 3-52
3 15 TOP END OVERHAUL: DISASSEMBLY
General 3-53
Stripping Motorcycle for Top End Repair 3-53
Cylinder Heads 3-54
Disassembling Rocker Covers 3-54
Removing Cylinder Head 3-56
Disassembling Push Rods and Covers 3-59
Cylinder and Piston 3-60
3 16 TOP END OVERHAUL: ASSEMBLY
General 3-62
Piston and Cylinder 3-62
Push Rods, Covers, and Retainers 3-63
Cylinder Head 3-65
Rocker Covers 3-68
Assembling Motorcycle After Top End Repair 3-71
3 17 BOTTOM END OVERHAUL:
DISASSEMBLY
General 3-73
Tappets 3-73
Oil Pump: XL Models 3-73
Gearcase Cover and Cam Gears: XL Models 3-73
Oil Pump Housing/Gearcase Cover and Cam Gears: XR
Models 3-74
Crankcase 3-76
Removing Piston Oil Jets 3-77
VIII TABLE OF CONTENTS
TABLE OF CONTENTS
Removing Cylinder Base Studs 3-77
3 18 BOTTOM END OVERHAUL: ASSEMBLY
Crankcase 3-78
Installing Piston Oil Jets 3-78
Installing Pinion Shaft Bearings 3-78
Installing Left Main Bearing 3-80
Assembling Crankcase Halves 3-80
Installing Cylinder Base Studs 3-83
Cam Gears and Gearcase Cover: XL Models 3-83
Cam Gears and Gearcase Cover: XR Models 3-86
Tappets 3-89
Assembling Top End of Engine 3-90
3 19 VALVE TAPPETS
General 3-91
Removal 3-91
Cleaning and Inspection 3-91
Installation 3-91
3 20 GEARCASE COVER AND CAM GEARS
General 3-92
Removal and Disassembly 3-92
Cleaning, Inspection and Repair 3-92
Cam and Pinion Gear Identification, Inspection and
Selection 3-92
Bushing Inspection and Removal: XL Only 3-92
Bushing Installation: XL Only 3-94
Cam Gear Bushings in Right Crankcase 3-94
Cam Gear Bushings (Except Rear Intake Bushing) in
Gearcase Cover 3-94
Rear Intake Cam Gear Bushing in Gearcase Cover 3-94
Pinion Shaft Bushing in Gearcase Cover 3-94
Bushing Reaming: XL Only 3-95
Cam Gear Bushings in Right Crankcase 3-95
Cam Gear Bushings (Except Rear Intake Bushing) in
Gearcase Cover 3-96
Rear Intake Cam Gear Bushing in Gearcase Cover 3-96
Pinion Shaft Bushing in Gearcase Cover 3-96
Assembly and Installation 3-97
3 21 CYLINDER HEAD
Removal 3-98
Disassembly 3-98
Cleaning and Inspection 3-100
Cylinder Heads 3-100
Rocker Arm Assemblies 3-100
Valves 3-102
Valve Seats 3-102
Valve Guides 3-102
Valve Springs 3-102
Spark Plug Threads 3-103
Push Rods 3-103
Replacing Rocker Arm Bushings 3-103
Replacing Valve Guides 3-104
Removal 3-104
Installation 3-105
Refacing Valve Seats 3-108
Replacing Valve Seats 3-110
Assembly 3-110
Installation 3-113
3 22 CYLINDER AND PISTON
Removal and Disassembly 3-114
Cleaning, Inspection and Repair 3-114
Checking Gasket Surface 3-114
Measuring Cylinder Bore 3-114
Measuring Piston to Cylinder Fit 3-115
Boring and Honing Cylinder 3-116
Fitting Piston Rings 3-116
Connecting Rod Bushings 3-118
Removing Upper Connecting Rod Bushings 3-118
Installing Upper Connecting Rod Bushings 3-120
Reaming Upper Connecting Rod Bushings 3-120
Honing Upper Connecting Rod Bushings 3-121
Repair 3-121
Assembly and Installation 3-121
3 23 CRANKCASE
General 3-122
Removal 3-122
Disassembly 3-123
Fitting Pinion Bearings 3-124
Bearing Selection 3-125
Inner Bearing Finish Example 3-127
Lapping Engine Main Bearing Races 3-128
Assembling Crankcase Halves 3-129
3 24 OIL PUMP: XL MODELS
General 3-130
Removal 3-131
Disassembly 3-131
Cleaning and Inspection 3-131
Assembly 3-131
Installation 3-132
3 25 OIL PUMP: XR MODELS
General 3-133
Disassembly 3-134
Cleaning and Inspection 3-135
Assembly 3-136
3 26 OIL FILTER MOUNT
General 3-137
Disassembly 3-137
Cleaning and Inspection 3-137
Assembly 3-137
3 27 OIL TANK
Oil Hose Routing: XL Models 3-138
Oil Line Routing: XR Models 3-138
Removal 3-140
Installation 3-142
FUEL SYSTEM
4 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 4-1
4 2 SPECIFICATIONS: FUEL SYSTEM
Specifications: 2009 Sportster Models 4-4
TABLE OF CONTENTS IX
TABLE OF CONTENTS
4 3 ELECTRONIC FUEL INJECTION (EFI)
Troubleshooting 4-5
4 4 AIR CLEANER: XL MODELS
Removal 4-6
Cleaning, Inspection and Repair 4-6
Installation 4-7
4 5 AIRBOX: XR MODELS
Removal 4-8
Installation 4-8
4 6 FUEL TANK: XL MODELS
General 4-9
Purging and Disconnecting Fuel Supply Hose 4-10
Removing Fuel Tank 4-10
Cleaning and Inspection 4-11
Installing Fuel Tank 4-11
Reconnecting Fuel Hose and Filling Fuel Tank 4-12
Vapor Valve 4-12
Console Replacement 4-13
Removal 4-13
Installation 4-14
4 7 FUEL TANK: XR MODELS
General 4-16
Purging and Disconnecting Fuel Supply Hose 4-16
Removing Fuel Tank 4-16
Disassemble Fuel Tank 4-18
Cleaning and Inspection 4-18
Assemble Fuel Tank 4-19
Installing Fuel Tank 4-19
Reconnecting Fuel Hose and Filling Fuel Tank 4-20
4 8 THROTTLE POSITION (TP) SENSOR
General 4-21
Removal: XL Models 4-22
Installation: XL Models 4-22
Removal: XR Models 4-23
Installation: XR Models 4-23
4 9 ENGINE TEMPERATURE (ET) SENSOR
General 4-25
Removal 4-25
Installation 4-26
4 10 INDUCTION MODULE: XL MODELS
General 4-28
Removal 4-28
Disassembly 4-30
Assembly 4-31
Installation 4-32
4 11 INDUCTION MODULE: XR MODELS
General 4-34
Removal 4-34
Disassembly 4-35
Assembly 4-36
Installation 4-36
4 12 IDLE AIR CONTROL (IAC)
General 4-38
Removal: XL Models 4-39
Installation: XL Models 4-39
Removal: XR Models 4-40
Installation: XR Models 4-41
4 13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR
General 4-42
Removal: XL Models 4-42
Installation: XL Models 4-43
Removal: XR Models 4-44
Installation: XR Models 4-44
4 14 OXYGEN SENSOR
General 4-46
Removal 4-46
Installation 4-47
4 15 EXHAUST SYSTEM: XL MODELS
General 4-48
Removal 4-49
Mufflers and Exhaust Pipes 4-49
Muffler Interconnect Bracket 4-49
Installation 4-50
Muffler Interconnect Bracket 4-50
Exhaust Pipes and Mufflers 4-50
4 16 EXHAUST SYSTEM: XR MODELS
General 4-52
Removal 4-52
Mufflers 4-52
Header Pipes 4-53
Installation 4-53
Header Pipes 4-53
Mufflers 4-53
4 17 FUEL INJECTORS
General 4-54
Removal 4-54
Installation 4-55
4 18 FUEL PUMP
General 4-57
Removal 4-57
Disassembly 4-58
Pressure Regulator and Filter Housing 4-58
Fuel Pump Assembly and Pump Bracket 4-59
Low Fuel Level Sensor Assembly 4-59
Fuel Pump/Sender Harness 4-59
Assembly 4-59
Fuel Pump/Sender Harness 4-59
Low Fuel Level Sensor Assembly 4-59
Fuel Pump Assembly and Pump Bracket 4-59
Pressure Regulator and Filter Housing 4-59
Installation 4-60
4 19 FUEL PRESSURE TEST
General 4-62
X TABLE OF CONTENTS
TABLE OF CONTENTS
Testing 4-62
4 20 INTAKE LEAK TEST
General 4-64
Leak Tester 4-64
Parts List 4-64
Tester Assembly 4-64
Tester Adjustment 4-64
Procedure 4-64
4 21 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS)
General 4-66
Charcoal Canister 4-67
Removal 4-67
Installation 4-68
Vapor Valve: XL Models 4-68
Removal 4-68
Installation 4-68
Hose Routing 4-69
Induction Module 4-69
Canister Hose Routings: XL Models 4-70
Canister Hose Routings: XR Models 4-70
DRIVE/TRANSMISSION
5 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 5-1
5 2 SPECIFICATIONS: DRIVE
2009 Sportster Specifications 5-3
5 3 PRIMARY CHAIN ADJUSTER
General 5-4
Removal 5-4
Primary Cover 5-4
Primary Chain Adjuster 5-6
Installation 5-6
Primary Chain Adjuster 5-6
Primary Cover 5-7
5 4 CLUTCH RELEASE MECHANISM
Removal and Disassembly 5-9
Cleaning, Inspection and Repair 5-10
Assembly and Installation 5-10
5 5 PRIMARY DRIVE AND CLUTCH: XL
MODELS
General 5-12
Removal 5-14
Disassembly 5-14
Inspection and Repair 5-15
Assembly 5-16
Installation 5-17
5 6 PRIMARY DRIVE AND CLUTCH: XR
MODELS
General 5-20
Removal 5-22
Disassembly 5-22
Clutch Pack Cleaning and Inspection 5-23
Adjusting Screw Disassembly/Assembly 5-24
Clutch Shell/Hub Inspection 5-24
Clutch Shell Bearing Replacement 5-25
Assembly 5-26
Installation 5-28
5 7 DRIVE BELT
Removal 5-30
XL Models 5-30
XR Models 5-31
Installation 5-31
XL Models 5-31
XR Models 5-32
Idler Pulley: XR Models Only 5-33
Removal 5-33
Installation 5-34
5 8 TRANSMISSION
General 5-35
5 9 CASE DISASSEMBLY FOR
TRANSMISSION REMOVAL
General 5-37
Engine Removal and Disassembly 5-37
5 10 TRANSMISSION REMOVAL AND
DISASSEMBLY
Transmission Removal From Left Crankcase 5-41
Mainshaft/Countershaft 5-44
Mainshaft Disassembly 5-45
Cleaning and Inspection 5-46
Countershaft Disassembly 5-46
Cleaning and Inspection 5-46
5 11 TRANSMISSION ASSEMBLY
Mainshaft Assembly 5-48
Countershaft Assembly 5-48
5 12 MAIN DRIVE GEAR AND BEARING
General 5-50
Removal 5-51
Main Drive Gear 5-51
Main Drive Gear Ball Bearing 5-52
Disassembly 5-52
Assembly 5-53
Installation 5-54
Main Drive Gear Bearing: XL Models 5-54
Main Drive Gear Bearing: XR Models 5-55
Main Drive Gear 5-55
Main Drive Gear Seal 5-57
5 13 TRANSMISSION RIGHT CASE
BEARINGS
Removal 5-59
Countershaft Needle Bearing 5-59
Shifter Drum Bushing 5-59
Installation 5-59
Countershaft Needle Bearing 5-59
Shifter Drum Bushing 5-59
TABLE OF CONTENTS XI
TABLE OF CONTENTS
5 14 TRANSMISSION LEFT CASE
BEARINGS
Removal 5-60
Mainshaft and Countershaft Bearings 5-60
Shifter Drum Bushing 5-60
Installation 5-60
Mainshaft and Countershaft Bearings 5-60
Shift Drum Bushing 5-60
5 15 TRANSMISSION INSTALLATION
General 5-61
Installation 5-61
Shifter Forks and Drum Assembly 5-62
Assembling Crankcases 5-63
Shifter Shaft Installation 5-65
5 16 TRANSMISSION SPROCKET
Removal 5-67
All Models 5-67
XL Models 5-67
XR Models 5-67
All Models 5-68
Installation 5-68
All Models 5-68
XL Models 5-69
XR Models 5-70
All Models 5-70
ELECTRICAL
6 1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter 6-1
6 2 SPECIFICATIONS: ELECTRICAL
Specifications: 2009 Sportster Models 6-4
6 3 VOLTAGE REGULATOR
General 6-5
Removal: XL Models 6-5
Installation: XL Models 6-6
Removal: XR Models 6-7
Installation: XR Models 6-8
6 4 FUSES AND RELAYS
General 6-10
Replacing Fuses 6-10
Replacing Relays 6-10
6 5 MAIN FUSE HOLDER
General 6-11
Replacement 6-11
6 6 SPEEDOMETER: XL SINGLE GAUGE
MODELS EXCEPT XL 883C/XL 1200C
Removal 6-12
Installation 6-12
6 7 SPEEDOMETER AND TACHOMETER:
XL DUAL GAUGE MODELS
Speedometer Removal 6-14
Speedometer Installation 6-14
Trip Odometer Reset Switch Replacement 6-15
Tachometer Removal 6-16
Tachometer Installation 6-16
6 8 SPEEDOMETER: XL 883C/XL 1200C
Removal 6-17
Installation 6-18
6 9 SPEEDOMETER AND TACHOMETER:
XR MODELS
Speedometer Removal 6-19
Speedometer Installation 6-19
Trip Odometer Reset Switch Replacement 6-21
Tachometer Removal 6-21
Tachometer Installation 6-21
6 10 TURN SIGNAL AND SECURITY
MODULE (TSM/TSSM/HFSM)
General 6-22
Testing 6-22
Removal 6-22
Installation 6-23
6 11 BATTERY CABLES
Removal 6-24
Installation 6-25
6 12 BATTERY TRAY
General 6-26
Removal 6-26
Installation 6-27
6 13 STARTER
General 6-29
Wiring Diagrams 6-29
Paint Touch-Up 6-29
Removal 6-29
Field Coil Assembly 6-29
Disassembly 6-29
Inspection 6-29
Assembly 6-30
Drive Assembly 6-31
Disassembly 6-31
Inspection 6-31
Assembly 6-31
Installation 6-32
6 14 STARTER SOLENOID
Solenoid Assembly 6-33
Disassembly 6-33
Assembly 6-33
Solenoid Plunger 6-33
Disassembly 6-33
Assembly 6-33
Solenoid Contacts 6-33
Disassembly 6-33
XII TABLE OF CONTENTS
TABLE OF CONTENTS
Assembly 6-34
6 15 IGNITION SYSTEM
Troubleshooting 6-36
6 16 IGNITION AND LIGHT SWITCH
General 6-37
Removal 6-37
Installation 6-37
6 17 ELECTRONIC CONTROL MODULE
(ECM)
General 6-39
Removal 6-39
XL Models 6-39
XR Models 6-39
Installation 6-39
XL Models 6-39
XR Models 6-39
6 18 SPARK PLUG CABLES
General 6-41
Removal 6-41
Installation 6-42
6 19 IGNITION COIL
General 6-44
Troubleshooting 6-44
Removal 6-44
Installation 6-45
6 20 CHARGING SYSTEM
General 6-47
Alternator 6-47
Voltage Regulator 6-47
6 21 HEADLAMP
Replacement: XL 883C/XL 1200C 6-48
Replacement: All Models Except XL 883C/XL 1200C 6-50
6 22 INDICATOR LAMP MODULE
General 6-52
Preliminary Disassembly: All Models 6-52
Replacement: XL 1200L and XL 1200N 6-52
Replacement: XL 883C and XL 1200C 6-53
Replacement: All Other Models 6-53
Reassembling Vehicle: All Models 6-54
6 23 TAIL LAMP: ALL MODELS EXCEPT XL
1200N
General 6-55
Bulb Replacement 6-55
Base Replacement 6-55
6 24 TURN SIGNALS
General 6-58
Bulb Replacement 6-58
Front Housing Replacement 6-58
Rear Housing Replacement 6-59
Preliminary Vehicle Disassembly: All Models 6-59
Disconnect Wiring: All Models Except XL 1200N 6-59
Disconnect Wiring: XL 1200N 6-60
Remove and Disassemble Turn Signal Assembly: All But
XR 1200 6-61
Reassemble and Install Turn Signal Assembly: All But XR
1200 6-62
Remove and Disassemble Turn Signal Assembly: XR
1200 6-63
Reassemble and Install Turn Signal Assembly: XR
1200 6-64
Connect Wiring: All Models Except XL 1200N 6-64
Connect Wiring: XL 1200N 6-64
Final Assembly: All Models 6-64
6 25 LICENSE PLATE LAMP MODULE: XL
1200N
General 6-65
Removal (Domestic Only) 6-65
Installation (Domestic Only) 6-65
Removal (HDI Only) 6-66
Installation (HDI Only) 6-68
6 26 REAR LIGHTING CONVERTER
MODULE: XL 1200N (DOMESTIC ONLY)
General 6-70
Removal 6-70
Installation 6-71
6 27 REAR STOP LAMP SWITCH
General 6-72
Replacement 6-72
6 28 CRANK POSITION SENSOR (CKP)
General 6-74
Removal 6-74
Installation 6-74
6 29 ALTERNATOR
Removal and Disassembly 6-75
Rotor 6-75
Stator 6-75
Cleaning and Inspection 6-76
Assembly and Installation 6-76
Stator 6-76
Rotor 6-77
Final Assembly 6-77
6 30 VEHICLE SPEED SENSOR (VSS)
General 6-78
Removal 6-78
Installation 6-78
6 31 NEUTRAL INDICATOR SWITCH
General 6-79
Replacement 6-79
6 32 MAIN WIRING HARNESS
General 6-81
Removal 6-81
Installation 6-82
TABLE OF CONTENTS XIII
TABLE OF CONTENTS
6 33 ELECTRICAL CADDIES
General 6-85
Voltage Regulator Caddy: XL Models Only 6-85
Removal 6-85
Installation 6-85
Wire Harness Caddy: XL Models 6-85
Removal 6-86
Installation 6-87
Wire Harness Caddy: XR Models 6-89
Removal 6-89
Installation 6-90
6 34 JIFFY STAND SWITCH:
INTERNATIONAL MODELS
General 6-91
Removal 6-91
Installation 6-92
6 35 OPTIONAL SECURITY SIREN
General 6-93
Removal 6-93
Disassembly 6-93
Battery Replacement 6-94
Schedule 6-94
Battery Replacement: Early Style Siren 6-94
Battery Replacement: Late Style Siren 6-94
Assembly 6-95
Installation 6-95
6 36 OIL PRESSURE SWITCH
General 6-96
Removal 6-96
Installation 6-97
6 37 HORN
Troubleshooting 6-98
Voltage Test 6-98
Replacement: Models with Front Mounted Horn 6-98
Replacement: Models with Side Mounted Horn 6-98
6 38 MAIN FUSE
General 6-100
Removal 6-100
Installation 6-100
6 39 HANDLEBAR SWITCH ASSEMBLIES
General 6-101
Repair Procedures 6-101
Connectors 6-102
6 40 RIGHT HANDLEBAR SWITCHES
Removal 6-103
Disassembly 6-103
Switch Repair/Replacement 6-104
Upper Housing Repair 6-104
Lower Housing Repair 6-105
Turn-Right Signal Switch 6-105
Front Stoplight Switch 6-105
Assembly 6-105
Installation 6-106
6 41 LEFT HANDLEBAR SWITCHES
Removal 6-109
Disassembly 6-109
Switch Repair/Replacement 6-109
Upper Housing Repair 6-109
Lower Housing Repair 6-110
Turn-Left Signal Switch 6-110
Clutch Interlock Switch 6-110
Assembly 6-110
Installation 6-111
APPENDIX A CONNECTOR REPAIR
A 1 AMP MULTILOCK CONNECTORS
AMP Multilock Connector Repair A-1
General A-1
Separating Pin and Socket Housings A-1
Mating Pin and Socket Housings A-1
Removing Terminals from Housing A-1
Inserting Terminals into Housing A-2
Preparing Wire Leads for Crimping A-2
Crimping Terminals to Leads A-3
Inspecting Crimped Terminals A-4
A 2 AUTOFUSE ELECTRICAL
CONNECTORS
Autofuse Connector Repair A-5
General A-5
Disassembly A-5
Assembly A-5
A 3 DELPHI CONNECTORS
Delphi Connector Repair A-6
General A-6
Separating Pin and Socket Housings A-6
Mating Pin and Socket Housings A-6
Removing Socket Terminals A-6
Installing Socket Terminals A-6
A 4 DELPHI MAIN FUSE HOUSING
Delphi Main Fuse Housing Repair A-8
General A-8
Removing Main Fuse A-8
Installing Main Fuse A-8
Removing Socket Terminals A-8
Installing Socket Terminals A-8
A 5 DEUTSCH ELECTRICAL CONNECTORS
Deutsch Connector Repair A-10
General A-10
Separating Pin and Socket Housings A-10
Mating Pin and Socket Housings A-10
Removing Socket Terminals A-10
Installing Socket Terminals A-10
Removing Pin Terminals A-12
Installing Pin Terminals A-12
Crimping Terminals A-13
XIV TABLE OF CONTENTS
TABLE OF CONTENTS
A 6 DEUTSCH STANDARD TERMINAL
REPAIR
Deutsch Standard Terminal Crimps A-14
Preparing Wire Leads for Crimping A-14
Crimping Terminal to Lead A-14
Inspecting Crimps A-14
A 7 DEUTSCH SOLID BARREL MINI
TERMINAL REPAIR
Deutsch Solid Barrel Terminal Crimps A-15
Preparing Wire Leads For Crimping A-15
Adjusting Crimper Tool A-15
Crimping a Barrel Contact To Wire Lead A-15
Inspecting Crimps A-15
A 8 DEUTSCH MINI TERMINAL REPAIR
Deutsch Mini Terminal Crimps A-17
Preparing Wire Leads for Crimping A-17
Crimping a Mini Terminal to Wire Lead A-17
Inspecting Crimps A-17
A 9 MOLEX CONNECTORS
Molex Connector Repair A-18
Separating Pin and Socket Housings A-18
Mating Pin and Socket Housings A-18
Removing Terminals A-18
Installing Terminals A-18
Crimp Terminal to Lead A-19
Prepare Lead A-19
Prepare Tool A-19
Position Terminal in the Punch/Die A-20
Insert Stripped Lead A-20
Crimp Terminal to Lead A-21
Inspect Crimp A-21
A 10 PACKARD 150 METRI-PACK
CONNECTORS
150 Metri-Pack Connector Repair A-22
General A-22
Separating Pin and Socket Housings A-22
Mating Pin and Socket Housings A-22
Removing Socket Terminal A-22
Inserting Socket Terminal A-22
A 11 PACKARD 280 METRI-PACK RELAY
AND FUSE BLOCK CONNECTORS
Fuse Block Repair A-24
Removing Socket Terminals A-24
Installing Socket Terminals A-24
Crimping Terminals A-24
A 12 PACKARD 480 METRI-PACK
CONNECTORS
480 Metri-Pack Connector Repair A-25
General A-25
Separating Pin and Socket Housings A-25
Mating Pin and Socket Housings A-25
Removing Socket Terminals A-25
Installing Socket Terminals A-25
A 13 PACKARD 630 METRI-PACK
CONNECTORS
630 Metri-Pack Connector Repair A-26
General A-26
Separating Pin and Socket Housings A-26
Mating Pin and Socket Housings A-26
Removing Socket Terminal A-26
Installing Socket Terminal A-26
A 14 PACKARD METRI-PACK TERMINALS
Metri-Pack Terminal Crimps A-27
Matching Terminal To Crimper A-27
Preparing Wire Lead A-27
Crimping Wire Core A-27
Crimping Insulation/Seal A-27
Inspecting Crimps A-28
A 15 PACKARD ECM CONNECTOR
Packard 100W Connector Repair A-29
General A-29
Separating Socket Housing From ECM A-29
Mating Socket Housing To ECM A-29
Removing Socket Terminal A-29
Installing Socket Terminal A-29
Crimping Terminals A-29
A 16 PACKARD MICRO-64 CONNECTORS
Packard Micro-64 Connector Repair A-31
General A-31
Separating Pin and Socket Housings A-31
Mating Pin and Socket Housings A-31
Removing Terminal A-31
Installing Terminal A-32
Preparing Wire Leads for Crimping A-32
Crimping Terminals A-32
Inspecting Crimps A-32
A 17 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair A-34
General A-34
Preparing Wire Leads A-34
Splicing Wire Leads A-34
Inspecting Seals A-34
APPENDIX B WIRING
B 1 CONNECTORS
Connector Locations B-1
Function/Location B-1
Place and Color B-1
Connector Number B-1
Repair Instructions B-1
B 2 WIRING DIAGRAMS
Wiring Diagram Information B-3
Wire Color Codes B-3
Wiring Diagram Symbols B-3
2009 Sportster Wiring Diagrams B-4
TABLE OF CONTENTS XV
TABLE OF CONTENTS
APPENDIX C CONVERSIONS
C 1 METRIC CONVERSION
Conversion Table C-1
C 2 FLUID CONVERSIONS
United States System C-2
Metric System C-2
British Imperial System C-2
C 3 TORQUE CONVERSIONS
United States System C-3
Metric System C-3
APPENDIX D COMPENSATING
SPROCKET
D 1 COMPENSATING SPROCKET
General D-1
Removal and Disassembly D-1
Cleaning, Inspection and Repair D-1
Sprocket Bearing Replacement D-1
Removal D-1
Installation D-2
Assembly and Installation D-2
APPENDIX E GLOSSARY
E 1 GLOSSARY
Acronyms and Abbreviations E-1
REFERENCE MATERIAL
TOOLS I
TORQUE VALUES IX
INDEX XXIX
XVI TABLE
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