Harley Davidson Sportster Models 2009. Service Repair Manual — page 28
2.41
RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS
RIGHT FOOTREST AND REAR BRAKE
PEDAL ASSEMBLY
Removal
NOTE
Right side access is improved by exhaust system removal.
See
4.15 EXHAUST SYSTEM: XL MODELS
1.
See
. Remove retaining ring (2), clevis pin
(5), footrest (1) and spring washer (3). Discard retaining
ring.
2.
Remove brake rod (8) from brake pedal (7) and master
cylinder bell crank (14).
3.
Remove retaining ring (16), screw (11) and clevis (4). Slide
brake pedal off clevis. Discard retaining ring.
4.
Remove two screws (9), footrest/brake pedal support
bracket (10) and j-clip (12) from frame (13).
Installation
1.
. Position j-clip (12) against frame as
shown. Mount footrest/brake pedal support bracket (10)
and j-clip to frame (13) with screws (9). Tighten to 45-50
ft-lbs (61-68 Nm).
2.
Slide brake pedal (7) onto clevis (4). Mount clevis on
footrest/brake pedal support bracket. Line up hole in clevis
with hole in support bracket. Secure with screw (11).
Tighten to 96-156 in-lbs (10.9-17.6 Nm). Install new
retaining ring (16) on end of clevis.
3.
Install footrest (1) on clevis with spring washer (3). Make
sure spring washer is positioned inside clevis with the
square edge toward the inside. Align holes and push clevis
pin (5) from top down through hole in clevis. Secure with
new retaining ring (2).
4.
Apply two drops of LOCTITE THREADLOCKER 243 (blue)
to threads of both brake rod ball stud screws.
5.
Thread one end of brake rod (8) into master cylinder bell
crank (14). Tighten to 120-180 in-lbs (13.6-20.4 Nm).
6.
Thread other end of brake rod into brake pedal. Tighten
to 120-180 in-lbs (13.6-20.4 Nm).
2009 Sportster Service: Chassis 2-175
7
6
4
2
1
3
5
9
10
12
11
16
13
15
14
8
sm02207
9.
1.
Screw (2)
Footrest
2.
10.
Retaining ring
Footrest/brake pedal support bracket
11.
3.
Screw
Spring washer
4.
12.
Clevis
J-clip
13.
5.
Frame
Clevis pin
6.
14.
Bushing
Bell crank
15.
7.
Rear brake master cylinder and bracket assembly
Brake pedal
8.
16.
Brake rod assembly
Retaining ring
Figure 2-257. Forward Controls - Brake Side
LEFT FOOTREST AND SHIFT LEVER
ASSEMBLY
Removal
1.
See
. Remove retaining ring (13), clevis pin
(17), footrest (16) and spring washer (15). Discard
retaining ring.
2.
Remove screw (21) and shifter peg (18).
3.
Remove shifter rod assembly (4) from shifter lever
assembly (12) and shift lever (3).
4.
Remove retaining ring (20), screw (10) and clevis (14).
Slide shifter lever assembly off clevis. Discard retaining
ring.
5.
Remove two screws (9), footrest/shifter lever support
bracket (8) and j-clip (7) from frame.
6.
Remove pinch screw (1), washer (2), shift lever (3) and
rubber washer (19) from transmission shift shaft.
2-176 2009 Sportster Service: Chassis
Installation
1.
See
. Install rubber washer (19) and shift
lever (3) onto transmission shifter shaft, with shift lever
arm pointing straight down. Secure with pinch screw (1)
and washer (2). Tighten pinch screw to 16-20 ft-lbs (21.7-
27.1 Nm).
2.
Mount j-clip (7) and footrest/shift lever support bracket (8)
to frame with two screws (9). Tighten to 45-50 ft-lbs (61-
68 Nm).
3.
Slide shifter lever assembly (12) onto clevis (14). Mount
clevis on footrest/shifter lever support bracket. Line up
hole in clevis with hole in support bracket. Secure with
screw (10). Tighten to 18-22 ft-lbs (24.4-29.9 Nm). Install
retaining ring (20) on end of clevis.
4.
Mount footrest (16) on clevis with spring washer (15). Make
sure spring washer is positioned inside clevis with the
square edge toward the inside. Align holes and push clevis
pin (17) from top down through hole in clevis. Secure with
new retaining ring (13).
5.
Thread screw (5) in one end of shifter rod assembly (4)
into shift lever (3). Tighten to 120-180 in-lbs (13.6-20.4
Nm).
6.
Thread screw (6) in other end of shifter rod into shift lever
assembly. Tighten to 120-180 in-lbs (13.6-20.4 Nm).
7.
If re-using shifter peg screw (21), clean screw threads and
apply one or two drops of LOCTITE THREADLOCKER
243 (blue) to threads.
NOTE
The previous step is not necessary for a new shifter peg screw
as it has a built-in lock patch.
8.
Install shifter peg (18) and secure with screw (21). Tighten
screw to 96-144 in-lbs (10.9-16.3 Nm)
20
10
7
8
9
11
12
13
14
15
16
17
18
6
4
5
3
1
2
19
21
sm02208
12.
1.
Shifter lever assembly
Pinch screw
2.
13.
Washer
Retaining ring
14.
3.
Clevis
Shift lever
4.
15.
Shifter rod assembly
Spring washer
16.
5.
Footrest
Screw
6.
17.
Screw
Clevis pin
18.
7.
Shifter peg
J-clip
8.
19.
Footrest/shifter lever support bracket
Rubber washer
20.
9.
Retaining ring
Screw (2)
10.
21.
Screw
Screw, shifter peg
11. Bushing
Figure 2-258. Forward Controls - Shifter Side
2009 Sportster Service: Chassis 2-177
ADJUSTING SHIFT PEDAL
The foot shift linkage is set at the factory and normally should
need no adjustment. However, if gears do not engage fully or
toe shifter travel is incorrect, adjust linkage rod as follows.
See
. Adjust shifter rod assembly (4) length until
shifter lever assembly (5) is at 45° as shown in the figure:
1.
Loosen lock nuts (3) on both ends of shifter rod.
2.
Remove screw (1) securing ball joint (2) to shifter lever
assembly.
3.
Turn ball joint or shifter rod to adjust rod length. Tempor-
arily attach ball joint to shifter lever assembly and check
angle. Make sure an equal number of threads are visible
on both ends of shifter rod.
4.
When angle of shift lever assembly is at 45°, install screw
(1). Tighten to 120-180 in-lbs (13.6-20.4 Nm).
5.
Holding shifter rod so that it does not turn, tighten lock
nuts on both ends.
5
3
4
2
1
sm01228
1.
Screw (2)
2.
Ball joint (2)
3.
Lock nut (2)
4.
Shifter rod assembly
5.
Shifter lever assembly
Figure 2-259. Adjusting Shift Pedal: Models with Forward
Controls
2-178 2009 Sportster Service: Chassis
2.42
RIDER FOOT CONTROLS: XR MODELS
RIGHT FOOTREST AND REAR BRAKE
PEDAL ASSEMBLY
Removal
1.
Remove exhaust system. See
.
2.
Remove clevis pin connecting master cylinder to brake
pedal. See
2.14 REAR BRAKE MASTER CYLINDER: XR
3.
If necesssary, remove wear peg (11).
4.
See
. Remove retaining ring (10) and washer
(9). Discard retaining ring.
5.
Remove clevis pin (5), spring (7), and footrest (8).
6.
Remove bolt (3), footrest clevis (6), and brake pedal (4).
7.
If necessary, remove bracket (1). The master cylinder
must be disconnected from the bracket or brake line dis-
connected prior to removing the two fasteners (2). See
2.14 REAR BRAKE MASTER CYLINDER: XR MODELS
.
10
11
9
8
7
6
1
4
2
2
5
3
sm05342
1.
Master cylinder/footrest bracket
2.
Fastener
3.
Footrest clevis bolt
4.
Brake pedal
5.
Clevis pin
6.
Footrest clevis
7.
Spring
8.
Footrest
9.
Washer
10. Retaining ring
11. Wear peg
Figure 2-260. Rider Foot Control, Right Side: XR Models
Installation
1.
If removed, install master cylinder/footrest bracket. See
2.14 REAR BRAKE MASTER CYLINDER: XR MODELS
2.
. Install brake pedal on footrest clevis
and install footrest clevis. Tighten bolt (3) to 20-24 ft-lbs
(27.1-32.5 Nm).
3.
Install footrest (8) and spring (7) on clevis and secure with
clevis pin (5). Install washer (9) and new retaining ring
(10).
4.
If removed, install wear peg and tighten to 72-108 in-lbs
(8.1-12.2 Nm).
5.
Connect brake pedal to master cylinder. See
BRAKE MASTER CYLINDER: XR MODELS
6.
Install exhaust system. See
.
LEFT FOOTREST AND SHIFT LEVER
ASSEMBLY
Removal
1.
See
. Remove fasteners (11) and remove
linkage (12).
2.
If necesssary, remove wear peg (9).
3.
Remove retaining ring (4) and washer (5). Discard
retaining ring.
4.
Remove clevis pin (10), spring (7), and footrest (8).
5.
Remove bolt (3), footrest clevis (6), and foot shift lever
(15).
6.
Remove shifter peg (13).
7.
If necessary, remove fasteners (2) and bracket (1).
2009 Sportster Service: Chassis 2-179
1
2
4
5
6
8
7
9
10
11
12
11
13
14
16
15
3
sm05348
1.
Bracket
2.
Fastener (2)
3.
Footrest clevis bolt
4.
Retaining ring
5.
Washer
6.
Footrest clevis
7.
Spring
8.
Footrest
9.
Wear peg
10. Clevis pin
11. Fastener (2)
12. Shift linkage
13. Shifter peg
14. Transmission shift lever
15. Foot shift lever
16. Bushing
Figure 2-261. Rider Foot Control, Left Side: XR Models
Installation
1.
See
. If removed, install bracket (1). Tighten
fasteners (2) to 45-50 ft-lbs (61.0-67.8 Nm).
2.
Install foot shift lever on footrest clevis and install footrest
clevis. Tighten bolt (3) to 20-24 ft-lbs (27.1-32.5 Nm).
3.
Install footrest (8) and spring (7) on clevis and secure with
clevis pin (10). Install washer (5) and new retaining ring
(4).
4.
Install shifter peg (13) and tighten to 96-144 in-lbs (10.9-
16.3 Nm).
5.
If removed, install wear peg and tighten to 72-108 in-lbs
(8.1-12.2 Nm).
6.
Connect linkage (12) between foot shift lever (15) and
transmission shift lever (14) using fasteners (11). Tighten
to 120-180 in-lbs (13.6-20.3 Nm).
7.
Check shift linkage adjustment and adjust as necessary.
ADJUSTING SHIFT PEDAL
The foot shift linkage is set at the factory and normally should
need no adjustment. However, if gears do not engage fully or
toe shifter travel is incorrect, adjust linkage rod as follows.
See
. Adjust shifter rod assembly (4) length until
shifter lever assembly (5) is at approximately 20° from hori-
zontal as shown in the figure.
1.
Loosen jam nut (3) on front end of shifter rod.
2.
Remove screw (1) securing ball joint (2) to shifter arm (6).
3.
Turn ball joint in one direction or the other to adjust rod
length as necessary. Temporarily attach ball joint to shifter
arm and check angle.
4.
when angle of shift lever assembly is at 20°, install screw
(1). Tighten to 120-180 in-lbs (13.6-20.4 Nm).
5.
Holding ball joint with a wrench on the flats, tighten jam
nut.
1
2
3
4
5
6
7
sm04910
1.
Screw
2.
Ball joint
3.
Jam nut
4.
Shifter rod
5.
Shifter lever assembly
6.
Shifter arm
7.
20°
Figure 2-262. Adjusting Shift Pedal: XR Models
2-180 2009 Sportster Service: Chassis
2.43
PASSENGER FOOTRESTS
GENERAL
Passenger footrest assemblies are standard equipment on
certain models only.
XL MODELS
Removal
1.
See
. Remove retaining ring (1), clevis pin
(2), footrest (3) and spring washer (4). Discard retaining
ring.
2.
Remove two screws (5) and footrest support bracket (6)
from frame (7).
Installation
NOTE
See
. On left side of vehicle, a B-clip (8) is posi-
tioned between footrest support bracket (6) and lower support
bracket hole on frame (7). Make sure this clip is positioned
between footrest support bracket and frame when attaching
support bracket in the next step.
1.
. Attach footrest support bracket (6) to
frame (7) with two screws (5). Tighten to 45-50 ft-lbs (61-
68 Nm).
2.
Install footrest (3) on footrest support bracket with spring
washer (4). Make sure spring washer is positioned inside
support bracket mounting boss with the square edge
toward the inside.
3.
Align holes and push clevis pin (2) from top down through
hole in support bracket. Secure with new retaining ring
(1).
7
8
6
5
4
2
3
1
sm02209
1.
Retaining ring
2.
Clevis pin
3.
Footrest
4.
Spring washer
5.
Screw (2)
6.
Footrest support bracket
7.
Frame
8.
B-clip (left side only)
Figure 2-263. Passenger Footrest Assembly (Not Standard
Equipment on Some Models)
XR MODELS
Removal
1.
. Remove retaining ring (1), clevis pin
(2), footrest (3) and spring washer (4). Discard retaining
ring.
2.
On right side of vehicle, remove screw (8) securing muffler
bracket (6) to footrest support bracket (7).
3.
Remove two screws (5) and footrest support bracket from
frame.
Installation
1.
See
. Attach footrest support bracket (7) to
frame with two screws (5). Tighten to 45-50 ft-lbs (61-68
Nm)).
2.
Attach muffler bracket (6) to footrest support bracket with
screw (8). Tighten to 15-19 ft-lbs (20.4-25.8 Nm).
3.
Install footrest (3) on footrest support bracket with spring
washer (4). Make sure spring washer is positioned inside
support bracket mounting boss with the square edge
toward the inside.
2009 Sportster Service: Chassis 2-181
4.
Align holes in footrest and support bracket and push clevis
pin (2) from top down through hole in support bracket.
Secure with new retaining ring (1).
1
2
3
4
6
7
8
5
sm04920
1.
Retaining ring
2.
Clevis pin
3.
Footrest
4.
Spring washer
5.
Screw (2)
6.
Muffler bracket (right side only)
7.
Footrest support bracket
8.
Screw (right side only)
Figure 2-264. Passenger Footrest Assembly: XR Models
(Right Side Shown)
2-182 2009 Sportster Service: Chassis
2.44
FORK LOCK
REMOVAL
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Unplug main fuse. See
.
3.
Prepare vehicle for fork lock replacement.
a.
All models: remove fuel tank. See
. Turn
front forks fully to the left.
b.
XL 883C/XL 1200C models: remove handlebar upper
clamp/speedometer housing. See
. Secure handlebar assembly out of the way.
4.
. See
. Using a 5/64 in. drill
bit, carefully drill a hole in the center of the lock pin.
NOTE
Take time to carefully orient drill bit to center of lock pin. If drill
bit slides off-center, removal of lock pin will be difficult.
5.
. To remove lock pin, insert a screw
extractor into the 5/64 in. hole. Hold body of screw
extractor with a pliers or tap handle and using a small
hammer gently "tap" on the pliers or tap handle to remove
lock pin.
6.
Remove lock assembly.
sm01230
Figure 2-265. Fork Lock Pin
sm01231
Figure 2-266. Drilling Lock Pin
sm01232
Figure 2-267. Removing Lock Pin
INSTALLATION
1.
Insert new lock assembly in frame lock housing.
2.
Align lock pin hole in new lock assembly with hole in the
frame lock housing.
3.
Drive new lock pin in position (flush with frame lock
housing).
2009 Sportster Service: Chassis 2-183
4.
Reassemble motorcycle.
a.
XL 883C/XL 1200C models: Install handlebar
assembly and upper clamp/speedometer housing.
See
b.
All models: install fuel tank. See
.
5.
Verify proper operation of fork lock.
a.
Turn front forks fully to the left.
b.
Insert key into fork lock. Turn key 90 degrees clock-
wise.
c.
Verify that front forks are locked and cannot be turned.
d.
Turn key 90 degrees counterclockwise and remove
from fork lock.
e.
Verify that front forks are now free to fully turn right
and left.
6.
Plug in main fuse. See
.
2-184 2009 Sportster Service: Chassis
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
ENGINE
NOTES
3.1
FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
NOTES
TORQUE VALUE
FASTENER
3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Tappets
9.0-12.4 Nm
80-110 in-lbs
Anti-rotation device mounting screw
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
129-142 Nm
95-105 ft-lbs
Axle nut, rear
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
129-142 Nm
95-105 ft-lbs
Axle nut, rear
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
3.4-4.5 Nm
30-40 in-lbs
Brake (rear) hose clamp-to-frame screw
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
2.3-2.8 Nm
20-25 in-lbs
Brake rear master cylinder reservoir
mounting screw
3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers
4.0-6.2 Nm
35-55 in-lbs
Breather screw
3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase
20.3-25.8 Nm
15-19 ft-lbs
Crankcase fastener
3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure
11-14 Nm
96-120 in-lbs
Cylinder head bolts
3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure
18-20 Nm
13-15 ft-lbs
Cylinder head bolts
3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure
11-14 Nm
96-120 in-lbs
Cylinder head bolts
3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure
18-20 Nm
13-15 ft-lbs
Cylinder head bolts
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
23.1-32.6 Nm
17-24 ft-lbs
Cylinder head bracket screw
3.16 TOP END OVERHAUL:
ASSEMBLY, Assembling Motorcycle After Top End
Repair
23.1-32.6 Nm
17-24 ft-lbs
Cylinder head bracket screw
3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Feed Assembly
29.8-35.3 Nm
22-26 ft-lbs
Cylinder head oil feed flare fitting, Preci-
sion Cooling
3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Feed Assembly
17.6-23.0 Nm
13-17 ft-lbs
Cylinder head oil feed line flare nut,
Precision Cooling
3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase
13.6-27.1 Nm
120-240 in-lbs
Cylinder stud
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
40.7-44.8 Nm
30-33 ft-lbs
Exhaust pipe clamp bracket screw
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
61.0-67.8 Nm
45-50 ft-lbs
Footrest bracket fastener
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
61.0-67.8 Nm
45-50 ft-lb
Footrest mount fastener
3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Return Lines
9.5-12.2 Nm
84-108 in-lbs
Front cylinder oil line retainer nut
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
81.4-95.0 Nm
60-70 ft-lbs
Front engine mount bolt
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
81.4-95.0 Nm
60-70 ft-lbs
Front engine mount bolt
2009 Sportster Service: Engine 3-1
sm01531
Figure 3-132. Valve Guide Seal Protector Sleeve
NOTES
•
Always use a protective sleeve on the valve stem keeper
groove when installing valve stem seal. If the seal is
installed without using the protective sleeve, the seal will
be damaged, causing leakage around the valve stem,
excessive oil consumption and valve sticking.
•
. The valve seal is incorporated into the
lower valve collar and is installed by hand. NO SPECIAL
TOOLS ARE REQUIRED.
•
The valve seal is completely installed when the lower valve
collar contacts the machined surface of the head.
sm01534
Figure 3-133. Valve Seal and Lower Valve Collar Assembly
(seal and lower collar replaced as assembly only)
sm01536
Figure 3-134. Valve Seal and Lower Valve Collar Assembly
Installation
4.
See
. Place a new seal and lower valve collar
assembly over valve stem and onto valve guide.
NOTES
•
Do not remove valve after seal is installed. Otherwise,
sharp edges on keeper groove will damage seal.
•
A single valve spring is used for each valve. The inner and
outer springs are combined into one progressively wound,
tapered spring.
5.
. Install valve spring (5) and upper collar
(4).
6.
. Compress valve spring with VALVE
SPRING COMPRESSOR (Part No. HD-34736-B).
7.
. Insert valve collar retainers (3) into
upper collar (4), making sure they engage groove in valve
stem. The retainer gaps should be equal.
8.
Release and remove VALVE SPRING COMPRESSOR.
9.
Repeat previous steps for remaining valve(s).
10. Install stabilizer link bracket (16) to front head with two
screws (17) and lock washers (18). Tighten to 55-65 ft-lbs
(74.6-88.2 Nm).
3-112 2009 Sportster Service: Engine
sm01537
Figure 3-135. Compress Valve Spring with Valve Spring
Compressor (Part No. HD-34736-B)
INSTALLATION
NOTE
Push rod covers and lower cover retainers MUST be installed
prior to installing cylinder heads. See
See
3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder Head
to install cylinder head onto engine.
2009 Sportster Service: Engine 3-113
3.22
CYLINDER AND PISTON
REMOVAL AND DISASSEMBLY
See
3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder
to remove cylinder and piston from engine.
CLEANING, INSPECTION AND REPAIR
TOOL NAME
PART NUMBER
TORQUE PLATE BOLTS
HD-33446-86
CYLINDER TORQUE PLATES
HD-33446-B
1.
Soak cylinder and piston in an aluminum-compatible
cleaner/solvent until deposits are soft, then clean with a
brush. Blow off loosened carbon and dirt particles and
wash in solvent.
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.
Clean oil passage in cylinder with low pressure com-
pressed air.
3.
Clean piston ring grooves with a piece of compression
ring ground to a chisel shape.
4.
Examine piston pin to see that it is not pitted or scored.
5.
Check piston pin bushing to see that it is not loose in
connecting rod, grooved, pitted or scored.
a.
A piston pin properly fitted to upper connecting rod
bushing has a 0.00125-0.00175 in. (0.0317-0.0444
mm) clearance in bushing.
b.
If piston pin-to-bushing clearance exceeds 0.002 in.
(0.0508 mm), replace worn parts. See
INDER AND PISTON, Connecting Rod Bushings
6.
Clean piston pin lock ring grooves.
7.
Examine piston and cylinder for cracks, burnt spots,
grooves and gouges.
NOTE
Check connecting rod for up and down play in lower bearings.
When up and down play is detected, flywheel and connecting
rod assembly must be replaced. This requires removing and
disassembling engine crankcase.
Checking Gasket Surface
NOTE
If either cylinder gasket surface does not meet flatness specific-
ations, replace cylinder and piston.
1.
. Check that cylinder top (head) gasket
surface is flat within 0.006 in. (0.15 mm). Lay a straight
edge across the surface, then try to insert a feeler gauge
between the straightedge and the gasket surface.
2.
Check that the cylinder base gasket surface is flat within
0.008 in. (0.20 mm). Lay a straightedge across the surface,
then try to insert a feeler gauge between the straightedge
and the gasket surface.
sm01539
Figure 3-136. Checking Gasket Surfaces
Measuring Cylinder Bore
1.
. Remove any burrs from the cylinder
gasket surfaces.
2.
Install a head and base gasket, and CYLINDER TORQUE
PLATES (Part No. HD-33446-B) and TORQUE PLATE
BOLTS (Part No. HD-33446-86) . Tighten the bolts using
the same method used when installing the cylinder head
screws. See
3.21 CYLINDER HEAD, Installation
.
NOTE
Torque plates, properly tightened and installed with gaskets,
simulate engine operating conditions. Measurements will vary
as much as 0.001 in. (0.025 mm) without torque plates.
3.
Take cylinder bore measurement in ring path, starting
about 1/2 in. (13 mm) from top of cylinder, measuring from
front to rear, and then side to side. Record readings.
4.
Repeat measurement at center, and then at bottom of ring
path. Record readings. This process will determine if cyl-
inder is out-of-round (or "egged") and will also show any
cylinder taper or bulge. Refer to
. If cylinder is
not scuffed or scored and is within service limit, see
3-114 2009 Sportster Service: Engine
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