Harley Davidson Sportster Models 2009. Service Repair Manual — page 23
6
3
8
7
5
4
1
6
2
3
sm01459
1.
Rear brake caliper
2.
Caliper mounting bracket
3.
Caliper bushing boot
4.
Caliper pin boot
5.
Bolt pin (caliper)
6.
Bolt pin (mounting bracket)
7.
Tapered shoulder
8.
Boot lip
Figure 2-127. Assembling Rear Brake Caliper to Mounting
Bracket
ASSEMBLY
NOTE
Use ONLY KS62F assembly grease for lubrication. Use of
D.O.T. 4 brake fluid will result in increased brake pedal travel.
1.
Lubricate the following parts prior to assembly using a
light coat of KS62F assembly grease from the service
parts kit. All other surfaces must be dry for assembly.
a.
Nose radius of piston. See
.
b.
All surfaces of piston seal and dust seal.
NOTE
A damaged piston bore will leak when reassembled. Do not
use metal objects to remove or install components in piston
bore. Prevent damage to bore by only using a wooden toothpick
when servicing caliper.
2.
See
. Install a new piston seal (3) and a new
dust seal (2) into piston bore.
3.
Carefully insert piston by hand, nose radius first (see
), into caliper bore. If installation shows res-
istance, remove piston and check that seals are properly
installed and fully seated in grooves.
4.
See
. Install bleeder valve (12) on caliper
housing if removed. Do not tighten bleeder valve at this
time.
5.
See
. Place caliper and mounting bracket
assembly on workbench as shown. Install pad spring in
channel. Press firmly into place.
sm01456
Figure 2-128. Piston Nose Radius
2-86 2009 Sportster Service: Chassis
sm01432
Figure 2-129. Rear Caliper Pad Spring
INSTALLATION
1.
. Before installing caliper, make sure that
retainer clip is properly installed on mounting bracket.
2.
See
. Place rear caliper assembly (6) onto
mounting bracket (1), being careful not to pinch or roll
boots over.
3.
Install rear brake caliper and mounting bracket assembly
onto vehicle.
NOTE
Brake caliper housing has a positive stop for banjo fitting. When
tightening banjo bolt into brake caliper in the next step, rotate
banjo fitting clockwise until it contacts positive stop.
4.
. Position a new washer (2) on each side
of hydraulic brake line (3) banjo fitting. Insert banjo bolt
(1) through washers and fitting. Thread bolt into caliper
housing. Tighten to 20-25 ft-lbs (27.1-33.9 Nm).
NOTE
The rear brake caliper does NOT use the same exact brake
pad set as the front left and front right (not present on all
models) calipers.
5.
See
. Insert brake pads (1) into caliper with
friction material on pad facing brake disc. Curved portion
of pad fits into recessed area of caliper. Make sure brake
pad front mounting tab (2) fits into slot (5) in caliper
mounting bracket (4).
6.
. Press brake pads (15) tightly up against
pad spring (2) and install pad pin (10). Tighten to 131-173
in-lbs (14.8-19.6 Nm).
NOTES
If pad pin does not fit, check the following:
•
You are using a set of pads, not two identical pads.
•
Pad spring orientation must match
•
See
. Pad front mounting tabs (2) must be
fully seated in mounting bracket slot (5).
•
Pads must be pushed tight up against pad spring before
pad pin is installed.
7.
See
. Install pad pin plug (9). Tighten to 18-25
in-lbs (2.0-2.9 Nm).
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTES
•
If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.
•
Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.
•
See
. Reservoir cover (2) may be removed
from rear brake master cylinder reservoir (1) to more easily
verify fluid level in reservoir.
8.
. If desired, remove reservoir cover: grasp
cover (2) and gently pull straight out from reservoir (1).
9.
Remove rear brake master cylinder reservoir cap (5). Add
HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID to reservoir
until fluid reaches upper fluid level (3). Do not overfill
reservoir. Do not reuse brake fluid.
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
10. Bleed brake system. See
A plugged or covered relief port can cause brake drag or
lock-up, which could lead to loss of control, resulting in
death or serious injury. (00288a)
2009 Sportster Service: Chassis 2-87
11. Verify proper operation of master cylinder relief port.
a.
Press against rear brake caliper to push caliper piston
back into its bore. This pushes brake fluid back
through master cylinder and verifies that relief port is
not plugged.
b.
Pump brake pedal until caliper piston pushes pads
against disc and pressure is returned to brake system.
12. Add HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID to
reservoir until fluid reaches upper fluid level.
13. If reservoir cover was removed, install cover on reservoir.
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
14. Test brake system.
a.
Turn ignition switch ON. Pump brake pedal to verify
operation of brake lamp.
b.
Test ride motorcycle at low speed. If brakes feel
spongy, bleed system again. See
NOTE
Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.
sm01460
Figure 2-130. Retainer Clip
2
3
5
1
4
6
sm03594
1.
Banjo bolt
2.
Washer (2)
3.
Rear brake line
4.
Brake caliper
5.
Caliper mounting bracket
6.
Damper
Figure 2-131. Rear Caliper Assembly
2
3
3
1
1
4
2
5
sm01462
1.
Brake pad
2.
Front mounting tab
3.
Pad pin hole
4.
Rear caliper mounting bracket
5.
Slot
Figure 2-132. Installing Rear Brake Pads
2-88 2009 Sportster Service: Chassis
sm01424
Figure 2-147. Bleeding Hydraulic System (typical; XL model
shown)
1
2
sm05497
1.
XR Models master cylinder
2.
XL Models master cylinder
Figure 2-148. Front Brake Master Cylinder Identification
2
4
4
5
5
1
1
2
8
7
3
6
10
11
9
8
8
sm01814
1.
Washer (dual front disc models: 6, all others: 4)
2.
Banjo bolt (dual front disc models: 3, all others:
2)
3.
Hydraulic brake line (single front disc models)
4.
Clamp
5.
Screw
6.
Hydraulic brake line (dual front disc XL models)
7.
Clamp (single front disc models)
8.
Screw with captive washer
9.
Clamp (dual front disc models)
10. Hydraulic brake line (dual front disc XR models)
11. Brake line manifold (dual front disc models)
Figure 2-149. Front Brake Line (typical)
Installation
NOTE
Master cylinder housings have various positive stops for banjo
fittings, based on the model being repaired. The front brake
systems as used on XR models and XL models employ different
master cylinder housings as shown in
. Never
intermix system components. When tightening the banjo bolt
in the next step, verify the banjo fitting is properly oriented and
contacts the positive stop.
1.
See
. Note that hydraulic brake line is made
up of thin tube construction and flexible hose sections.
Position new washers (1) on each side of banjo fitting on
end of brake line with shortest flexible hose section. Insert
2-98 2009 Sportster Service: Chassis
banjo bolt (2) through washers and banjo fitting. Loosely
install banjo bolt into master cylinder.
2.
Route brake line downward in front of right handlebar, and
inward behind fork brackets. Install clamp (4) around lower
fitting of upper flexible hose section. Loosely attach clamp
to front fork upper bracket (XL models) or lower bracket
(XR models) with screw (5).
3.
Continue routing brake line downward crossing to left side
of the vehicle under front fork lower bracket.
4.
Clamp brake line to stem at bottom of front fork lower
bracket.
a.
Dual front disc models: Install screw with captive
washer (8) through brake line manifold (11) and clamp
(9). Loosely thread screw into front fork lower bracket
stem.
b.
Single front disc models: Install clamp (7) around top
fitting of long flexible hose section. Loosely attach
clamp to front fork lower bracket stem with screw with
captive washer (8).
NOTE
Single front disc models must have line positioned to maintain
a gap between line and lower fork bracket. Dual front disc
models will self-align creating a gap by default, but the gap
should be visually confirmed.
5.
Single front disc models: See
. Measure dis-
tance between front brake line metal tubing and lower fork
bracket adjacent to pinch bolt. Move brake line assembly
forward or back until there is a 1/4 in. (6.35 mm) gap
between brake line and lower fork bracket.
Do not bend metal brake line. Bending brake line could
cause metal fatigue and brake failure, which could result
in death or serious injury. (00543b)
6.
See
. While maintaining proper gap between
brake line and lower fork bracket, tighten screw (8) to 120-
168 in-lbs (13.6-19.0 Nm).
7.
Position new washers (1) on each side of banjo fitting at
free end of brake line. Insert banjo bolt(s) (2, 3) through
washers and banjo fitting of each caliper. Loosely install
banjo bolt into each caliper.
NOTE
Master cylinder housing has a positive stop for banjo fitting.
When tightening banjo bolt into master cylinder in the next
step, rotate banjo fitting clockwise until it contacts positive stop.
8.
Tighten banjo bolt (2) into master cylinder to 20-25 ft-lbs
(27.1-33.9 Nm).
9.
Tighten screw (5) to 45-65 in-lbs (5.1-7.4 Nm).
NOTE
Brake caliper housing has a positive stop for banjo fitting. When
tightening banjo bolt into brake caliper in the next step, rotate
banjo fitting clockwise until it contacts positive stop.
10. Tighten banjo bolt into brake caliper to 20-25 ft-lbs (27.1-
33.9 Nm). Dual front disc models: repeat this step for other
front brake caliper.
11. Fill master cylinder with new HARLEY-DAVIDSON D.O.T.
4 BRAKE FLUID and bleed brakes. See
. Test operation of brake
lever.
12. Tighten bleeder valve to 35-61 in-lbs (4.0-6.9 Nm). Install
bleeder nipple cap. Dual front disc models: repeat this
step for other front brake caliper.
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
13. Test ride motorcycle. If front brake feels spongy, bleed
system again. See
.
1
3
2
sm01464
1.
Front brake line
2.
Lower fork bracket pinch bolt
3.
Ruler
Figure 2-150. Measuring Front Brake Line Clearance
REAR BRAKE LINE: XL MODELS
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
2009 Sportster Service: Chassis 2-99
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTE
If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.
Removal
1.
Drain rear brake master cylinder reservoir. See
BRAKE MASTER CYLINDER RESERVOIR
.
2.
Remove bleeder nipple cap from bleeder valve on rear
brake caliper. Install end of a length of 5/16 in. (7.9 mm)
I.D. clear plastic tubing over caliper bleeder valve, while
placing free end in a suitable container. Open bleeder
valve about 1/2 turn. Pump brake pedal to drain brake
fluid. Close bleeder valve.
3.
See
. Unplug harness connectors [121] from
stop lamp switch (7).
4.
Remove banjo bolt (2) and washers (1) to detach rear
brake line (3) from master cylinder body and rear brake
caliper. Discard washers.
5.
Remove screw (5) to detach brake line clamp (4) with
bushing (12) from rear fork.
6.
Remove screw (10) to detach brake line clamp (9) from
battery tray bracket.
7.
Remove screw (11) securing brake line/switch tee (6) to
battery tray bracket.
8.
Feed brake line up through B-clamp (8).
9.
Hold hex body of brake line/switch tee with an open-end
wrench. Using a 1.0-in. six-point deep socket, remove stop
lamp switch from brake line/switch tee.
2
5
12
4
6
7
8
2
11
3
10
9
1
1
sm01815
1.
Washer (4)
2.
Banjo bolt (2)
3.
Rear brake line
4.
Clamp
5.
Screw
6.
Brake line/switch tee
7.
Stop lamp switch assembly
8.
B-clamp
9.
Clamp
10. Screw
11. Screw
12. Bushing
Figure 2-151. Rear Brake Line: XL Models
Installation
1.
. Thread stop lamp switch (7) into brake
line/switch tee (6) on new rear brake line (3). Hold hex
body of brake line/switch tee with an open-end wrench.
Using a 1.0-in. six-point deep socket, tighten stop lamp
switch assembly to 80-123 in-lbs (9.0-13.9 Nm).
2.
Feed rear brake line down through B-clamp (8).
3.
Position brake line/switch tee mounting bracket on battery
tray bracket. Secure with screw (11). Tighten to 72-120
in-lbs (8.14-13.6 Nm).
4.
Install clamp (9) and screw (10) to secure rear brake hose
to battery tray bracket. Tighten screw to 30-40 in-lbs (3.4-
4.5 Nm).
NOTE
When installing clamp (4), bushing (12) and screw (5) in the
next step, make sure to adjust brake hose length between rear
caliper and clamp so there is no extra length. Do not twist or
stretch brake hose. Make sure bushing sits squarely in clamp
and around hose.
5.
Install clamp (4) with bushing (12) and screw (5), to secure
rear brake hose to rear fork. Tighten screw to 30-40 in-
lbs (3.4-4.5 Nm).
2-100 2009 Sportster Service: Chassis
NOTE
Master cylinder and brake caliper housings have a positive
stop for banjo fitting. When tightening banjo bolt into master
cylinder and brake caliper in the next step, rotate banjo fitting
clockwise until it contacts positive stop.
6.
Position new washers (1) on each side of banjo fittings
by rear brake master cylinder and rear brake caliper. Insert
banjo bolts (2) through washers and banjo fittings. Tighten
to 20-25 ft-lbs (27.1-33.9 Nm).
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
NOTE
Rear brake master cylinder reservoir must be in a level position
when filling and checking fluid level.
7.
Position motorcycle upright (not resting on jiffy stand). Fill
rear brake master cylinder reservoir with HARLEY-DAV-
IDSON D.O.T. 4 BRAKE FLUID and bleed brake system.
See
1.8 BLEEDING HYDRAULIC BRAKE SYSTEM
8.
Tighten bleeder valve to 35-61 in-lbs (4.0-6.9 Nm). Install
bleeder nipple cap.
9.
Turn the ignition/light switch ON. Test operation of brake
lamp with the rear brake applied.
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
10. Test ride motorcycle. If rear brake feels spongy, bleed
system again. See
.
REAR BRAKE LINE: XR MODELS
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTE
If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.
Removal
1.
Drain rear brake master cylinder reservoir. See
BRAKE MASTER CYLINDER RESERVOIR
2.
Remove bleeder nipple cap from bleeder valve on rear
brake caliper. Install end of a length of 5/16 in. (7.9 mm)
I.D. clear plastic tubing over caliper bleeder valve, while
placing free end in a suitable container. Open bleeder
valve about 1/2 turn. Pump brake pedal to drain brake
fluid. Close bleeder valve.
3.
. Unplug harness connectors [121] from
stop lamp switch (2).
4.
Remove banjo bolts (4) and washers (5) to detach rear
brake line (3) from master cylinder body and rear brake
caliper. Discard washers.
5.
Remove fasteners (7) to detach brake line clamps (6) from
rear fork.
6.
Remove fasteners (8) securing brake line bracket/switch
tee (1) to lower frame.
7.
Hold hex body of brake line bracket/switch tee with an
open-end wrench. Using a 1.0-in. six-point deep socket,
remove stop lamp switch from brake line bracket/switch
tee assembly.
8.
If necessary, remove clamp and bushing (9).
2009 Sportster Service: Chassis 2-101
4
5
2
3
4
8
9
1
5
7
6
7
sm05316
1.
Brake line bracket/switch tee
2.
Stop lamp switch assembly
3.
Rear brake line
4.
Banjo bolt (2)
5.
Washer (4)
6.
Clamp (2)
7.
Fastener (2)
8.
Fastener (2)
9.
Clamp and bushing
Figure 2-152. Rear Brake Line: XR Models
Installation
1.
. Thread stop lamp switch (2) into brake
line bracket/switch tee (1) on rear brake line (3). Hold hex
body of brake line bracket/switch tee with an open-end
wrench. Using a 1.0-in. six-point deep socket, tighten stop
lamp switch assembly to 80-123 in-lbs (9.0-13.9 Nm).
2.
If removed, install clamp and bushing (9).
3.
Route brake line assembly to master cylinder and brake
caliper. Loosely install new washers (5) and banjo bolts
(4) to hold line in place.
4.
Position brake line bracket/switch tee on lower frame and
secure with fasteners (8). Tighten to 17-22 in-lbs (1.9-2.5
Nm).
5.
Connect harness connectors [121] to brake lamp switch
(2).
NOTE
Master cylinder and brake caliper housings have a positive
stop for banjo fitting. When tightening banjo bolt into master
cylinder and brake caliper in the next step, rotate banjo fitting
clockwise until it contacts positive stop.
6.
With new washers (5) on each side of banjo fittings, tighten
banjo bolts (4) to 20-25 ft-lbs (27.1-33.9 Nm).
7.
Secure brake line to bottom of rear fork with clamps (6)
and fasteners (7).
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
NOTE
Rear brake master cylinder reservoir must be in a level position
when filling and checking fluid level.
8.
Position motorcycle upright (not resting on jiffy stand). Fill
rear brake master cylinder reservoir with HARLEY-DAV-
IDSON D.O.T. 4 BRAKE FLUID and bleed brake system.
See
1.8 BLEEDING HYDRAULIC BRAKE SYSTEM
.
9.
Tighten bleeder valve to 35-61 in-lbs (4.0-6.9 Nm). Install
bleeder nipple cap.
10. Turn the ignition/light switch ON. Test operation of brake
lamp with the rear brake applied.
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
11. Test ride motorcycle. If rear brake feels spongy, bleed
system again. See
.
2-102 2009 Sportster Service: Chassis
2.19
TIRES
GENERAL
Use only Harley-Davidson approved tires. See a Harley-
Davidson dealer. Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)
Be sure tires are properly inflated, balanced and have
adequate tread. Inspect your tires regularly and see a
Harley-Davidson dealer for replacements. Riding with
excessively worn, unbalanced or under-inflated tires can
adversely affect stability and handling, which could result
in death or serious injury. (00014a)
New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the stack
compresses the tires and closes down the beads.
Tires should be inspected for punctures, cuts, breaks and wear
at least weekly.
. The tread wear indicator bars will appear
on tire tread surfaces when 1/32 in. (0.8 mm) or less of tread
remains. Always remove tires from service before they reach
the tread wear indicator bars.
New tires are needed if any of the following conditions exist.
See
1.
Tire wear indicator bars are visible on the tread surfaces.
2.
Tire cords or fabric are visible through cracked sidewalls,
snags or deep cuts.
3.
A bump, bulge or split in the tire.
4.
Puncture, cut or other damage to the tire that cannot be
repaired.
1
2
sm02177
1.
Sidewall
2.
Tread surface
Figure 2-153. Tread Wear Indicators (Typical)
REMOVAL
NOTE
Care must be taken when removing and installing tire to prevent
cosmetic damage to wheel. This is especially true with wheels
that feature painted surfaces.
1.
Remove wheel from motorcycle:
a.
Front wheel: see
b.
Rear wheel: see
2.
Deflate tire.
NOTE
On tube type wheels, it is not necessary to completely remove
tire from rim. Removing one side allows the tube to be replaced
and allows for inspection of tire.
3.
Loosen both tire beads from rim flange. In most cases, a
bead breaker machine will be required to loosen the beads
from the rim.
4.
Remove tire.
2009 Sportster Service: Chassis 2-103
CLEANING, INSPECTION AND REPAIR
1.
Clean the inside of tire and outer surface of tube.
2.
If rim is dirty or rusty, clean with a stiff wire brush.
3.
Check wheels for lateral and radial runout before installing
a new tire.
a.
Models with laced wheels: see
b.
Models with cast wheels: see
.
4.
Inspect the tire and tube for wear and damage. Inspect
tread depth. Replace worn tires. Replace damaged tubes.
Replace punctured or damaged tires. In some cases, small
punctures in the tread area may be repaired from within
the demounted tire by a Harley-Davidson dealer. Speed
should NOT exceed 50 mph (80 km/h) for the first 24 hours
after repair, and the repaired tire should NEVER be used
over 80 mph (130 km/h). Failure to follow this warning
could result in death or serious injury. (00015a)
5.
Tubeless tires may be repaired in the tread area only if
the puncture is 1/4 in. (6.4 mm) or smaller. All repairs must
be made from inside the tire.
6.
Acceptable repair method involves the use of a patch and
plug combination.
INSTALLATION
Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)
Do not exceed manufacturer's recommended pressure to
seat beads. Exceeding recommended bead seat pressure
can cause tire rim assembly to burst, which could result
in death or serious injury. (00282a)
Do not inflate tire beyond maximum pressure as specified
on sidewall. Over inflated tires can blow out, which could
result in death or serious injury. (00027a)
For tire pressures, see
Some tires have arrows molded into the tire sidewall. These
tires should be mounted on the rim with the arrow pointing in
the direction of forward rotation. The colored dot on the sidewall
is a balance mark and should be located next to the valve stem
hole.
Tube Type Tires
Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a Harley-Davidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on
the rim or cause tire failure, which could result in death
or serious injury. (00023a)
Use inner tubes on laced (wire spoked) wheels. Using
tubeless tires on laced wheels can cause air leaks, which
could result in death or serious injury. (00025a)
NOTES
•
For correct tire and tube types, see
•
Whenever a tube type tire is replaced, the tube should
also be replaced. Inner tubes should be patched only as
an emergency measure. Replace a damaged or patched
tube as soon as possible. Rim bands must be used on all
laced wheels.
1.
. On laced wheels, install a rim strip into
the rim well. Make sure no spokes protrude through
nipples, and be sure to align the valve stem hole in rim
strip with valve stem hole in rim.
2.
Install tube and tire.
sm02466
Figure 2-154. Installing Rim Strip
2-104 2009 Sportster Service: Chassis
Tubeless Tires
Only install original equipment tire valves and valve caps.
A valve, or valve and cap combination, that is too long or
too heavy can strike adjacent components and damage
the valve, causing rapid tire deflation. Rapid tire deflation
can cause loss of vehicle control, which could result in
death or serious injury. (00281a)
1.
. On tubeless wheels, damaged or
leaking valve stems must be replaced. Install rubber
grommet (3) on valve stem.
2.
Insert valve stem into rim hole.
3.
Install metal washer (2).
4.
Install nut and tighten to 12-15 in-lbs (1.4-1.7 Nm).
5.
Install tire.
1
3
2
sm02467
1.
Nut
2.
Metal washer
3.
Rubber grommet
Figure 2-155. Tubeless Tire Valve Stem
CHECKING TIRE RUNOUT
Lateral Runout
1.
. Turn wheel on axle and measure
amount of displacement from a fixed point to tire sidewall.
2.
Tire tread lateral runout should be no more than 0.090 in.
(2.29 mm). If runout exceeds this specification, remove
tire from rim, and check rim bead side runout to see if rim
is at fault.
3.
If rim bead seat runout is less than 0.030 in. (0.76 mm),
then tire is at fault and must be replaced. If rim bead seat
runout is greater than 0.030 in. (0.76 mm), correct by
tightening selected spoke nipples (laced wheels) or replace
wheel (cast wheels). Install tire and check tire tread radial
runout again.
sm01803
Figure 2-156. Checking Tire Lateral Runout
Radial Runout
1.
. Turn wheel on axle and measure tread
radial runout.
2.
Tire tread radial runout should not be greater than 0.090
in. (2.29 mm). If runout exceeds this specification, remove
tire from rim and check rim bead runout to determine if
rim is at fault.
3.
If rim bead seat runout is less than 0.030 in. (0.76 mm),
then tire is at fault and must be replaced. If rim bead seat
runout is greater than 0.030 in. (0.76 mm), correct by
tightening selected spoke nipples (laced wheels) or replace
wheel (cast wheels). Install tire and check tire tread radial
runout again.
sm01804
Figure 2-157. Checking Tire Radial Runout
2009 Sportster Service: Chassis 2-105
WHEEL BALANCING
TOOL NAME
PART NUMBER
WHEEL TRUING STAND
HD-99500-80
Wheel balancing is recommended to improve handling, and to
reduce vibration, especially at high road speeds.
In most cases, static balancing using WHEEL TRUING
STAND (Part No. HD-99500-80) will produce satisfactory res-
ults. However, dynamic balancing, utilizing a wheel spinner,
can be used to produce finer tolerances for best high-speed
handling characteristics. Follow the instructions supplied with
the balance machine you are using.
The maximum weight permissible to accomplish balance is 3-
1/2 oz. (99.2 g) (total weight applied to the rim). Wheels should
be balanced to within 1/2 oz. (14 g) at 60 mph (97 km/h).
Weights for Laced Wheels
Harley-Davidson specifies the following spoke balance weights,
which are crimped over the spoke nipple.
Table 2-23. Laced Wheel Balance Weights
HD
PART NUMBER
WEIGHT (MASS)
GRAMS
OZ. (U.S.)
95578-41
14
1/2
95581-47
21
3/4
95582-47
28
1
Weights for Cast Wheels
Harley-Davidson specifies the following cast wheel balance
weights, which have special self-adhesive backings.
Table 2-24. Cast Wheel Balance Weights
HD PART
NUMBER
FINISH
WEIGHT (MASS)
GRAMS
OZ. (U.S.)
95594-84
black
7
1/4
95595-84
silver
7
1/4
These weights are applied to the flat surface of the wheel rim
according to the following procedures.
1.
Make sure that area of application is completely clean,
dry, and free of oil and grease.
NOTE
If 1 oz. (28 g) or more of weight must be added at one location,
split the amount so that half is applied to each side of rim.
2.
Remove paper backing from weight. Apply three drops of
LOCTITE® SUPERBONDER® 420 to the adhesive side
of the weight. Place the weight on flat surface of wheel
rim. Press weight firmly in place, and hold for ten seconds.
3.
Allow eight hours for adhesive to cure completely before
using wheel.
2-106 2009 Sportster Service: Chassis
2.20
LEFT SIDE COVER
GENERAL
See
. The left side cover provides access to the
battery (1), fuses (3, 4) and diagnostic electrical connector (5).
No tools are required to open or close the cover.
See
. The left side cover is
secured to the motorcycle by two upper slots that fit into clips
(XL models) or two molded-in posts that fit into grommets (XR
models). The side cover is also secured to the vehicle by a
bottom slot that fits onto a mounting tab on the battery tray.
NOTE
The left side cover does not need to be completely removed
from the vehicle to access the battery or fuses.
5
2
4
3
1
sm01342
1.
Battery
2.
Positive (+) battery terminal (under protective
rubber boot)
3.
Main fuse and holder
4.
System fuses and relays
5.
Diagnostic connector (data link)
Figure 2-158. Main Fuse and Battery Location: All Models
(XL Model Shown)
OPENING LEFT SIDE COVER
1.
Place a clean, dry cloth over rear brake master cylinder
reservoir and left passenger foot peg (if equipped). This
will protect left side cover from damage.
2.
. Grasp left side cover
at upper corners and gently pull away from plastic
mounting clips (XL models) or grommets (XR models) on
frame.
3
4
2
1
sm01416
1.
Mounting clips (on frame)
2.
Mounting tab (on battery tray)
3.
Side cover mounting slots (top)
4.
Side cover mounting slot (bottom)
Figure 2-159. Left Side Cover: XL Models
2009 Sportster Service: Chassis 2-107
1
2
3
4
sm05351
1.
Mounting grommets (on frame)
2.
Mounting tab (on battery tray)
3.
Side cover mounting posts (top)
4.
Side cover mounting slot (bottom)
Figure 2-160. Left Side Cover: XR Models
1
3
4
2
1
2
sm01417
1.
Battery tray assembly
2.
Mounting tab
3.
Side cover (closed)
4.
Side cover (open)
Figure 2-161. Left Side Cover Bottom Mount: All Models
3.
See
. While rotating top of cover out away
from motorcycle, slide cover down slightly so mounting
slot on cover slides down mounting tab (2) on battery tray
assembly (1). See
. Side cover (3) will now
rest on top of rear brake master cylinder reservoir and left
passenger footrest (if equipped) with slot (2) hanging off
bottom of mounting tab (1).
Leaning or placing tools on side cover could cause
damage to cover and/or mounting tab on battery tray.
(00523b)
3
1
2
sm01418
1.
Side cover mounting tab (on battery tray)
2.
Mounting slot (bottom of left side cover)
3.
Left side cover
Figure 2-162. Left Side Cover in Open Position: All Models
(XL Model Shown)
CLOSING LEFT SIDE COVER
1.
. Grasp top corners of side cover (3).
While rotating top of cover up toward motorcycle, gently
pull cover up so that mounting slot (2) slides up mounting
tab (1).
2.
Press top of side cover into place:
a.
XL models: see
. Line up top slots of
side cover with mounting clips (1) on motorcycle
frame, aligning with front clip first. Press top of side
cover into clips until snug.
b.
XR models: see
. Line up molded-in
posts in top of side cover with mounting grommets
on motorcycle frame. Press posts in side cover into
grommets until snug.
NOTE
Side cover should snap into place with minimal pressure. Using
excessive force or striking side cover to close it can damage
mounting clips (XL models) or molded-in posts (XR models).
REMOVING LEFT SIDE COVER
NOTE
It is rarely necessary to remove the left side cover completely.
However, if left side cover removal is necessary, use the fol-
lowing procedure.
2-108 2009 Sportster Service: Chassis
1.
See
. Grasp side cover at
upper corners and gently pull away from plastic mounting
clips (XL models) or grommets (XR models) on frame.
2.
See
. Lift side cover up and tilt cover to the
rear of the motorcycle. With a slight back and forth rocking
motion, pull up gently until cover disengages from
mounting tab on battery tray.
sm01419
Figure 2-163. Removing Left Side Cover: All Models (XL
Model Shown)
INSTALLING LEFT SIDE COVER
NOTE
It is rarely necessary to remove the left side cover completely.
However, if left side cover has been removed, reinstall cover
as described in the following procedure.
1.
. Position side cover over battery tray
assembly with slot in bottom of cover resting on mounting
tab on battery tray.
2.
Gently press downward on side cover until slot snaps
down over mounting tab.
3.
Now close left side cover. See
.
2009 Sportster Service: Chassis 2-109
2.21
FRONT FORK: XL MODELS
GENERAL
The front fork consists of two telescoping tube/slider assem-
blies. Each tube/slider assembly has an internal compression
spring, which supports the forward weight of the vehicle/rider
and extends and retracts to cushion the ride over rough or
irregular road surfaces. An oil-filled damping mechanism con-
trols the telescoping action of each tube/slider assembly.
REMOVAL
1.
Remove front brake caliper(s). See
.
2.
Remove front wheel assembly. See
3.
Remove front fender mounting screws and lock nuts.
Remove fender. See
.
4.
See
. Loosen, but do not remove, slider tube
caps (12).
5.
Loosen front fork upper and lower bracket pinch screws
(11 and 14). Remove fork assemblies (13) from fork
brackets.
DISASSEMBLY
1.
See
. Remove drain screw and washer (19)
from slider (16). Remove tube cap (7) from slider tube (9).
Drain fork oil. Remove o-ring (6) from tube cap.
2.
Remove spring (5) from slider tube.
3.
All except XL 1200L: Remove spring collar (20) and
spring washer (21) from slider tube.
4.
All except XL 1200N: Remove cover (11).
NOTE
. The XL 1200N is equipped with fork gaiters
(2) instead of metal covers. The lower lip (3) of the fork gaiter
fits into the groove at the upper end of the fork slider (1). The
upper end of the fork gaiter fits tightly around the slider tube,
just below the front fork lower bracket (4).
5.
XL 1200N: See
. Peel back lower lip (3) of
fork gaiter (2) from slider groove and slide fork gaiter up
and off end of slider tube.
6.
See
. Remove dust seal (12). Compress
internal circle clip (13). Remove clip from groove in top of
slider bore.
7.
Remove screw (18) and washer (17) from bottom of slider.
NOTE
Since there is little resistance to damper tube (3) rotation within
slider tube (9) when removing screw (18), use an air impact
wrench for best results.
8.
Withdraw slider tube (9) from slider until lower bushing
(10) on slider tube contacts upper bushing (1) in slider.
Use lower bushing on slider tube in a slide hammer motion
to gently tap out oil seal (14), spacer (2) and upper bushing
from slider bore.
9.
Remove sleeve (15). Sleeve will be found within slider or
on bottom end of damper tube (3).
10. Insert a small diameter rod through opening in bottom of
slider tube to remove damper tube assembly.
11. Remove rebound spring (8) from damper tube.
12. Remove damper tube ring(s) (4) from damper tube.
13. Remove lower bushing from damper tube only if replace-
ment is necessary.
2-110 2009 Sportster Service: Chassis
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