Harley Davidson Sportster Models 2009. Service Repair Manual — page 26

2009 Sportster Service: Chassis 2-143

CLEANING, INSPECTION AND REPAIR

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)

Clean all parts in a non-flammable cleaning solvent. Blow dry
with low pressure compressed air. Replace cables if frayed,
kinked or bent.

ASSEMBLY AND INSTALLATION

Figure 2-216

. Apply a light coating of graphite to the

handlebar (10) and the inside surface of the upper and
lower housings (9, 11).

Install spring (5), throttle friction screw (13) and friction
spring (8) in lower housing (11).

Attach cable assemblies (2, 3) to lower housing. See

Figure 2-217

. Throttle control cable (4) has a 5/16 in. (7.9

mm) fitting end and is positioned to front of lower housing.
Idle control cable (3) has a 1/4 in. (6.3 mm) fitting end and
is positioned to rear of lower housing.

Figure 2-216

. Install throttle control grip (12) over end

of right handlebar (10). Position lower housing (11) onto
right handlebar, engaging lower housing with throttle
control grip. Position ferrules (1) over cable ball ends, then
seat ferrules (with cables attached) in their respective
notches of the throttle control grip.

Install upper housing (9) over right handlebar and secure
to lower housing using screws (7). Tighten screws to 35-45
in-lbs (4.0-5.1 Nm).

XL Models: See

Figure 2-218

. Route control cables for-

ward from throttle control grip, forward of front fork upper
bracket, downward between right slider tube and head-
lamp, rearward along right side of frame steering head
and frame backbone, over ignition switch housing, between
coil bracket and frame, and downward to induction module.

XR Models: See

Figure 2-219

. Route cables forward

between right fork and brake hose (1), then back between
the forks above the lower fork bracket. Pass cables
through wire retainer (2) on lower fork and continue above
the front cylinder toward the induction module.

Figure 2-217

. Install idle control cable (3) housing

into inboard (idle) cable guide (9) on induction module.

Install throttle control cable (4) housing and spring into
outboard cable guide (10) on induction module.

10. XL Models: See

Figure 2-215

. Place throttle cables (4)

into channel in right wire harness caddy (1) and secure
with two cable straps (5). Note that forward cable strap
also secures instrument connector [20] and rear cable
strap secures wiring harnesses on other side of caddy
wall.

Be sure that steering is smooth and free without interfer-
ence. Interference with steering could result in loss of
vehicle control and death or serious injury. (00371a)

•

Be sure cables are not pinched between the frame and/or
forks.

•

Be sure throttle/idle control cables do not pull tight when
handlebars are turned fully to left or right fork stops.

11. Adjust control cables. See

1.27 THROTTLE CONTROL,

Cable Adjustment

12. XL Models: See

Figure 2-215

. Mount left wire harness

caddy (2) to right wire harness caddy (1). Secure with
screw (3) and tighten.

13. Install air cleaner assembly.

14. Install fuel tank and connect fuel hose. See

4.6 FUEL

TANK: XL MODELS

4.7 FUEL TANK: XR MODELS

15. XR Models: See

Figure 2-219

. Secure cables in loop

retainer (3) and attach retainer to the bottom of the fuel
tank.

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)

16. Install seat.

17. Plug in main fuse. See

sm01215

Figure 2-218. Throttle Control Cable Routing: XL Models

2-144 2009 Sportster Service: Chassis

sm05332

Brake hose

Wire retainer

Loop retainer

Figure 2-219. Throttle Control Cable Routing: XR Models

For clutch adjustment, see

2009 Sportster Service: Chassis 2-145

2.31

CLUTCH CONTROL

GENERAL

1.13 CLUTCH

For clutch replacement, see

5.5 PRIMARY DRIVE AND

CLUTCH: XL MODELS

REMOVAL AND DISASSEMBLY

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

2.40 RIDER FOOT CONTROLS: XL MODELS

Clutch Cable: Lower

Models equipped with mid-mount foot controls: remove
left side rider footrest and mounting bracket assembly.
See

EQUIPPED WITH MID-MOUNT CONTROLS

2.42 RIDER FOOT CONTROLS: XR MODELS

for removal

procedure.

Figure 2-220

. Slide rubber boot (1) on clutch cable

adjuster (2) upward to expose adjuster mechanism.
Loosen jam nut (3) from adjuster. Turn adjuster to shorten
cable housing until there is a large amount of freeplay at
clutch hand lever. See

1.13 CLUTCH

See

Figure 2-221

. Remove six screws (1) and clutch

inspection cover (2). Exercise caution to avoid damaging
or dislodging quad ring (7) from groove in primary cover
(9).

Slide hex lockplate with attached spring (3) from flats of
adjusting screw assembly (8).

Turn adjusting screw assembly clockwise to release ramp
assembly (5) and coupling (6). As the adjusting screw is
turned, ramp assembly moves forward. Remove nut (4)
from end of adjusting screw.

Remove hook of ramp from cable coupling. Remove clutch
cable end (11) from slot in coupling. Remove coupling and
ramp assembly.

Remove cable end fitting (12) and remove clutch cable
(13) lower section from primary cover. Remove o-ring (10)
from cable end fitting. Discard o-ring.

Clean all metal parts in a non-volatile cleaning solution or
solvent.

sm01829

Rubber boot

Cable adjuster

Jam nut

Cable end

Figure 2-220. Clutch Cable Adjuster Mechanism

2-146 2009 Sportster Service: Chassis

sm01830

13.

Clutch cable

Quad ring

Screw (6)

14.

Clutch inspection cover

Outer ramp

Clutch adjusting screw
assembly

15.

Hex lockplate and spring

Ball (3)

16.

Primary cover

Inner ramp

Nut

17.

10.

Ramp assembly (see items
14-17)

Retaining ring

O-ring

11. Clutch cable end

12.

Coupling

Cable end fitting

Figure 2-221. Clutch Release Mechanism

Clutch Lever and Clutch Cable: Upper

See

. Remove retaining ring (3) and pivot pin

(6). Discard retaining ring.

Remove clutch lever (1) from clutch lever bracket (5).

Remove clutch cable pin (2). Disconnect clutch cable (4)
upper section from lever.

Remove bushing (9) from clutch lever. Bushing has a collar
on one end and can only be removed from top of lever.

Remove screw (10) and anti-rattle spring (11).

Clutch Hand Control

See

. Loosen set screw (12) and remove turn

signal assembly (16) from clutch lever bracket (5).

Loosen and remove lock nut (14) and lock washer (13),
and lift mirror (15) from clutch lever bracket.

Remove two screws and washers (7) and retainers (17)
from clutch control clamp (8).

Remove clutch control clamp (8) and clutch lever bracket
from left handlebar.

NOTE

See

Figure 2-222

. You may need to loosen two screws of left

handlebar switch housing to remove clutch control clamp (8)
and clutch lever bracket (5) from left handlebar.

2009 Sportster Service: Chassis 2-147

sm01831a

10.

Screw

Clutch lever

11.

Clutch cable pin

Anti-rattle spring

12.

Set screw

Retaining ring

13.

Clutch cable

Lock washer

14.

Lock nut

Clutch lever bracket

15.

Pivot pin

Mirror

16.

Turn signal assembly

Screw and washer (2)

17.

Clutch control clamp

Retainer (2)

Bushing

Figure 2-222. Clutch Hand Control

ASSEMBLY AND INSTALLATION

Clutch Hand Control

. Position clutch control clamp (8) and

clutch lever bracket (5) onto left handlebar. Hold clamp
and bracket assembly firmly against left handlebar switch
housing.

Secure components to left handlebar using two screws
and washers (7) and retainers (17). Tighten to 108-132
in-lbs (12.2-14.9 Nm).

Install mirror (15), secure with lock nut (14) and lock
washer (13). Position mirror for best rearward visibility.
Tighten lock nut to 96-144 in-lbs (10.9-16.3 Nm).

Install turn signal (16) and secure with set screw (12).
Position so turn signal lens faces directly forward and turn
signal does not strike fuel tank when handlebars are turned
full left. Tighten set screw to 96-120 in-lbs (10.9-13.6 Nm).

NOTE

If two screws of left handlebar switch housing were loosened
during clutch hand control removal, tighten to 35-45 in-lbs
(4.0-5.1 Nm).

2-148 2009 Sportster Service: Chassis

Clutch Lever and Clutch Cable: Upper

. Install anti-rattle spring (11) and screw

(10) onto clutch lever (1). Tighten screw to 8-13 in-lbs
(0.9-1.5 Nm).

Install bushing (9) in clutch lever. Bushing has a collar on
one end and must be installed from top of lever.

Connect end of clutch cable (4) upper section to clutch
lever (1) using clutch cable pin (2).

Position lever within clutch lever bracket (5), install pivot
pin (6) and secure with new retaining ring (3).

Clutch Cable: Lower

2.40 RIDER FOOT CONTROLS: XL

Figure 2-223

. If not yet done, route clutch cable (3)

forward from clutch lever (1), downward to outboard side
of left front fork slider tube, through two clips (6) on left
front frame downtube, and then rearward to primary cover
(4).

See

Figure 2-221

. Install new o-ring (10) over cable end

fitting (12) of clutch cable (13) lower section. Screw fitting
into primary cover (9). Tighten to 36-108 in-lbs (4.1-12.2
Nm).

Fit coupling (6) over cable end (11) with the rounded side
inboard, the ramp connector button outboard. With

retaining ring side of ramp assembly (5) facing inward,
place hook of ramp around coupling button and rotate
assembly counterclockwise until tang on inner ramp (16)
fits in slot of primary cover.

Thread nut (4) on adjusting screw assembly (8) until slot
of screw is accessible with a screwdriver. Fit nut hex into
recess of outer ramp (14). Turn adjusting screw counter-
clockwise until resistance is felt. Then back off adjusting
screw 1/4 turn.

Install hex lockplate with spring (3) onto flats of adjusting
screw assembly (8). If necessary, turn adjusting screw
clockwise slightly so that lockplate slides onto flats while
also fitting within recess of outer ramp.

Verify that quad ring (7) is fully seated in groove of primary
cover (9). Install clutch inspection cover (2) and secure
with six screws (1). Tighten screws in a crosswise pattern
to 84-108 in-lbs (9.5-12.2 Nm).

Models equipped with mid-mount foot controls: install
left side rider footrest and mounting bracket assembly.
Tighten footrest bracket mounting screws to 45-50 ft-lbs
(61-68 Nm). See

MODELS EQUIPPED WITH MID-MOUNT CONTROLS

2.42 RIDER FOOT CONTROLS: XR MODELS

for

installation procedure.

sm01832

Cable end fitting

Clutch lever

Cable adjuster boot

Clip (2)

Front brake caliper

Clutch cable

Primary cover

Front brake line

Figure 2-223. Clutch Cable and Front Brake Line Routings - Left Side

Finish

Plug in main fuse. See

2009 Sportster Service: Chassis 2-149

2.32

HANDLEBARS

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

All Models

Unplug main fuse. See

2.10 FRONT BRAKE MASTER CYL-

Remove two screws securing clutch control assembly to
left side of handlebar. See

2.31 CLUTCH CONTROL

Remove two screws securing left handlebar switch
assembly to handlebar. See

6.41 LEFT HANDLEBAR

SWITCHES

. Let wires carefully support the switch

assembly.

Remove left handlebar grip.

Remove front brake master cylinder assembly from right
handlebar. See

INDER

XL 883C and XL 1200C

Figure 2-224

. Cut and remove four wiring harness

retainers (10). When cutting retainers, be careful not to
cut into wiring harnesses. Discard retainers.

Loosen, but do not remove, two control housing screws
(8).

Remove two screws (16) and riser cover (15).

Remove four screws (3) and upper handlebar
clamp/speedometer housing (2). Detach handlebar (5)
from riser.

Slide right hand control and throttle assembly (4, 6, 9) off
detached handlebar.

If removing riser (14), remove bolts (11), washers (12) and
riser from upper fork bracket (13).

2-150 2009 Sportster Service: Chassis

sm01827

Lower control housing

Handlebar grip

10.

Upper handlebar clamp/Speedometer housing

Wire harness retainer (4)

11.

Bolt (2)

Screw (4)

12.

Upper control housing

Washer (2)

13.

Upper fork bracket

Handlebar

14.

Throttle grip and sleeve

Handlebar riser

15.

Riser cover

Throttle adjusting assembly

16.

Screw (2)

Figure 2-224. Handlebars: XL 883C; XL 1200C

All XL Models Except XL 883C, XL 1200C

See

Figure 2-225

. Cut and remove four wiring harness

retainers (12). When cutting retainers, be careful not to
cut into wiring harnesses. Discard retainers.

Loosen, but do not remove, two control housing screws
(10).

If removing lower handlebar clamps (13, 17), loosen, but
do not remove, two bolts (15) securing lower handlebar
clamps to upper fork bracket (16).

Remove screws (4) and instrument bracket (3) (if
equipped), upper handlebar clamp (5) or instrument
bracket (2).

Detach handlebar (7) from lower handlebar clamps.

Slide right hand control housing and throttle assembly (6,
8, 11) off detached handlebar.

If removing lower handlebar clamps (13, 17), remove two
bolts (15), washers (14) and lower handlebar clamps from
upper fork bracket (16).

2009 Sportster Service: Chassis 2-151

sm05353

10.

Screw (2)

Handlebar grip

11.

Upper handlebar clamp/instrument bracket
(XL1200L/N)

Lower control housing

12. Wire harness retainer (4)

13.

Bolt-on instrument bracket (XL 883/L/R; XL 1200R)

Lower right handlebar clamp

14.

Washer (2)

Screw (4)

15.

Upper handlebar clamp

Bolt (2)

16.

Upper fork bracket

Upper control housing

17.

Handlebar

Lower left handlebar clamp

Throttle grip and sleeve

Throttle adjusting assembly

Figure 2-225. Handlebars: XL 883L/R; XL 1200L/N/R

XR1200

See

Figure 2-226

. Cut and remove four wiring harness

retainers (12). When cutting retainers, be careful not to
cut into wiring harnesses. Discard retainers.

Loosen, but do not remove, two control housing screws
(10).

Remove two front screws (3) and washers (4). Remove
instrument bracket (2).

Remove two rear screws (3) and upper clamp (5).

Detach handlebar (7) from upper fork bracket (13).

Slide right hand control housing and throttle assembly (6,
8, 11) off detached handlebar.

2-152 2009 Sportster Service: Chassis

sm05354

Throttle grip and sleeve

Handlebar grip

Instrument bracket

Throttle adjusting assembly

10.

Screw (2)

Screw (4)

11.

Washer (2)

Lower control housing

12.

Wire harness retainer (4)

Upper handlebar clamp

13.

Upper control housing

Upper fork bracket

Handlebar

Figure 2-226. Handlebars: XR1200

INSTALLATION

XL 883C and XL 1200C

Figure 2-224

. If riser (14) was removed, secure riser

to upper fork bracket (13) with two bolts (11) and washers
(12). Make sure handlebar wiring harnesses are routed
behind and inside riser. Tighten bolts to 30-40 ft-lbs (40.7-
54.3 Nm).

Slide right handlebar control housing and throttle assembly
(4, 6, 9) onto right end of handlebar (5). Position handlebar
on lower handlebar clamp.

Place upper handlebar clamp/speedometer housing (2)
in position and thread four screws (3) in place.

See

Figure 2-227

. Adjust handlebars to desired position.

Tighten front screws (2) first, to 12-18 ft-lbs (16.3-24.4
Nm). Then tighten rear screws (3) to 12-18 ft-lbs (16.3-
24.4 Nm).

Figure 2-224

. Be sure handlebar wiring harnesses

are routed properly and are not pinched. Install riser cover
(15) and screws (16). Tighten to 8-12 in-lbs (0.9-1.4 Nm).

2009 Sportster Service: Chassis 2-153

sm03865

Lower clamp

Front screw (2) (tighten first)

Rear screw (2)

Upper clamp

Figure 2-227. Handlebar Riser: XL 883C/XL 1200C

All XL Models Except XL 883C, XL 1200C

Figure 2-225

. If lower handlebar clamps (13, 17) were

removed, secure clamps to upper fork bracket (16) with
bolts (15) and washers (14). Finger tighten bolts only at
this time. Make sure wiring harnesses are routed between
lower handlebar clamps.

Slide right handlebar control housing and throttle assembly
(6, 8, 11) onto right end of handlebar (7). Position
handlebar on lower handlebar clamps.

Place upper handlebar clamp (5) or clamp/instrument
bracket (2) in position and install four screws (4).

Models with bolt-on instrument bracket:

Figure 2-229

. Place spacers (6) over two front

mounting holes of upper handlebar clamp.

Position instrument bracket (5) over two front holes
of upper handlebar clamp and install two screws (4)
and washers (8).

See

Figure 2-228

. Adjust handlebars to desired position.

Tighten rear screws first, to 12-18 ft-lbs (16.3-24.4 Nm).
Then tighten front screws to 12-18 ft-lbs (16.3-24.4 Nm).

See

Figure 2-225

. Tighten lower handlebar clamp bolts

(15) to 30-40 ft-lbs (40.7-54.3 Nm).

sm03867

Lower clamp (2)

Cast-in spacer (2)

Rear screw (2) (tighten first)

Front screw (2)

Upper clamp

Figure 2-228. Handlebar Riser: XL 1200L/XL 1200N

sm03866

Lower clamp (2)

Cast-in spacer (2)

Rear screw (2) (tighten first)

Front screw (2)

Instrument bracket

Spacer

Upper clamp

Washer (2)

Figure 2-229. Handlebar Clamp: XL Models with Bolt-On

Instrument Bracket

XR1200

See

Figure 2-226

. Slide right handlebar control housing

and throttle assembly (6, 8, 11) onto right end of handlebar
(7). Position handlebar on upper fork bracket (13).

Place upper handlebar clamp (5) in position and install
rear screws (3).

Place instrument bracket in position and install front screws
(3) and washers (4).

2.10 FRONT BRAKE MASTER CYLINDER

2-154 2009 Sportster Service: Chassis

Adjust handlebars to desired position. Tighten rear screws
first, to 12-18 ft-lbs (16.3-24.4 Nm). Then tighten front
screws to 12-18 ft-lbs (16.3-24.4 Nm).

All Models

Install front brake master cylinder assembly. See

Install new left hand grip in place as follows:

Using a piece of emery cloth, rough grip end of left
handlebar.

NOTE

Before applying adhesive in the next step, clean the left
handlebar with acetone.

Apply LOCTITE PRISM PRIMER (770) to inside of
hand grip. Remove any excess PRISM PRIMER with
a clean cloth. Wait two minutes for PRISM PRIMER
to set before attempting the next step.

Apply LOCTITE PRISM SUPERBONDER (411) to
inside of hand grip. Install new hand grip on left
handlebar.

NOTE

SUPERBONDER will set in four minutes and be fully cured
in 24 hours.

Position left hand control and loosely install hand control
clamp screws. See

6.41 LEFT HANDLEBAR SWITCHES

Attach clutch control assembly to left side of handlebar.
Tighten screws to 108-132 in-lbs (12.2-14.9 Nm). See

2.31 CLUTCH CONTROL

Tighten left hand control clamp screws to 35-45 in-lbs
(4.0-5.1 Nm).

Tighten right hand control clamp screws to 35-45 in-lbs
(4.0-5.1 Nm).

Wrap four new wiring harness retainers (item 12,

or item 10,

.) around handlebar wiring harnesses and

push retainers into holes in handlebar.

Plug in main fuse. See

Verify the following:

Clutch cable adjustment/operation.

Proper throttle cable operation.

All electrical switch functions.

Proper brake operation and brake lamp function.

2009 Sportster Service: Chassis 2-155

2.33

FRONT FENDER

XL MODELS

NOTE

Be careful when removing or installing fender assembly, to
avoid scratching the paint. If necessary, cover the fender with
a clean shop towel to prevent damage.

Removal

Figure 2-230

. Remove four screws (1) and lock nuts

(2) to detach front fender (3) from front fork sliders.

Carefully remove fender from between front fork sliders.

Installation

See

Figure 2-230

. Carefully position front fender (3)

between right and left front fork sliders.

Secure fender using four screws (1) and lock nuts (2).
Tighten to 96-156 in-lbs (10.9-17.6 Nm).

sm02203

Screw (4)

Lock nuts (4)

Front fender

Figure 2-230. Front Fender: XL Models

XR MODELS

NOTE

Be careful when removing or installing fender assembly, to
avoid scratching the paint. If necessary, cover the fender with
a clean shop towel to prevent damage.

Removal

See

Figure 2-231

. Remove four screws (2) to detach front

fender (5) from front fork sliders.

Carefully remove fender and fender bracket assembly
from between front fork sliders.

Remove four screws (1) and nuts (3) to detach front fender
from fender bracket.

Installation

See

Figure 2-231

. carefully position fender bracket (4)

over front fender (5). Secure with four screws (1) and nuts
(3). Tighten to 36-60 in-lbs (4.1-6.8 Nm).

Carefully position front fender and fender bracket assembly
between right and left front fork sliders.

Secure front fender assembly using four screws (2).
Tighten to 15-19 ft-lbs (20.4-25.8 Nm).

sm04891

Screw (4)

Nut (4)

Fender bracket

Front fender

Figure 2-231. Front Fender: XR Models

FENDER AND LICENSE PLATE BRACKET: XL 1200N

2-156 2009 Sportster Service: Chassis

2.34

REAR FENDER: ALL XL MODELS EXCEPT XL
1200N

GENERAL

For rear fender and convertible side mount license plate bracket
removal and installation on XL 1200N model, see

2.35 REAR

REMOVAL

Remove seat.

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

Figure 2-232

. Remove two screws (6) and tail lamp

lens (7) from tail lamp base assembly (11). Twist tail lamp
bulb socket (9) 1/4 turn counterclockwise and remove from
lens.

sm02204

15.

Washer

Rear fender

16.

License plate bracket assembly

Turn signal assembly

17.

Turn signal stalk (2)

Screw (3)

18.

Nut (3)

Screw (2)

19.

Washer (4)

Washer

20.

Screw (2)

21.

Rear fender strut cover (2)

Tail lamp lens

22.

Bulb

Nut (4)

23.

Nut plate (2)

Socket assembly

10.

24.

Screw w/captive washer

Fender seat nut kit

25.

11.

Rear fender brace

Tail lamp base assembly

12.

26.

Clip nut

Rear fender extension

27.

13.

Frame

Screw

14.

28.

Seat post

Wire retention bracket (2)

Figure 2-232. Rear Fender Assembly

2009 Sportster Service: Chassis 2-157

Figure 2-233

. Note location of electrical connectors

on tail lamp circuit board. Depress latches on turn signal
connectors (1, 2) and tail lamp connector (4). Unplug
connectors from rear lighting circuit board.

Figure 2-235

. Unplug rear lighting connector assembly

[7] (2). Depress external latch and use a rocking motion
to separate connector halves.

See

Figure 2-236

. Depress latch (3) and unplug ECM

connector [78B] (2). Place ECM harness out of the way.

Gently bend back ECM latches (4) and lift ECM off locating
pins on ECM caddy (9).

H-DSSS equipped models: Gently bend back antenna
latch (7) and lift security antenna (5) out of recess. Release
antenna harness from harness retainer (8) in ECM caddy.
Place antenna and harness out of the way.

sm03346

Left turn signal connector [18]

Right turn signal connector [19]

Rear lighting power connector [94]

Tail lamp connector [93]

Screw with washer

Figure 2-233. Tail Lamp Housing

– AMP

sm03352

Orange with white tracer

Brown

Blue

Red with yellow tracer

Violet

Black

Figure 2-234. Tail Lamp Connector [94] (Secondary Lock

Open)

sm01217

Engine harness connector [145]

Rear lighting connector [7]

Seat post

Flat washer

Frame crossmember tab

Figure 2-235. Rear Lighting Connector Location