Harley Davidson Sportster Models 2009. Service Repair Manual — page 7

Protect fuel tank with a clean, soft cover.

Figure 6-22

. Remove two screws (8) and riser cover

(9) from back of handlebar riser (4). See

2.32 HANDLE-

BARS

NOTE

It is not necessary to remove the trip odometer reset switch
boot from the back of the speedometer housing in order to
remove the speedometer.

Remove two screws (5) holding speedometer (1) to
speedometer housing/handlebar clamp (3).

Using small diameter rod or Allen wrench, gently press
through bottom condensation/vent hole in speedometer
housing/handlebar clamp to push speedometer from
housing.

Holding speedometer to prevent damage, depress tabs
to separate connector [39B] (7) from speedometer.
Remove speedometer.

Inspect gasket, speedometer connector [39] and wiring,
trip odometer reset switch and wiring, and trip reset boot.
Repair or replace as required.

sm01274

Speedometer mounting hole

Speedometer connector [39]

Trip odometer reset switch in square boss

Condensation/vent hole

Figure 6-21. Speedometer Housing/Handlebar Clamp

(XL883C/XL 1200C)

A.16 PACKARD MICRO-64 CONNECTORS

2009 Sportster Service: Electrical 6-17

sm01377

Speedometer

Gasket

Speedometer housing/handlebar clamp

Handlebar riser

Screw (2)

Screw (4)

Speedometer harness connector [39B]

Screw (2)

Riser cover

Figure 6-22. Speedometer Components (XL 883C/XL 1200C)

INSTALLATION

TOOL NAME

PART NUMBER

CRIMPING TOOL

HD-45929

If replacing the trip odometer switch:

Push the trip reset socket terminals out the front of
the speedometer socket connector half [39B]. See

Cut off the socket terminals and pull the faulty switch
out of the connector.

Push the wires of a replacement switch through the
speedometer connector (sockets 8, 11) and crimp
new socket terminals using CRIMPING TOOL (Part
No. HD-45929), on replacement switch wiring.

Draw the terminal back into the connector until the
terminal seats.

Figure 6-22

. If removed, install gasket (2) in speedo-

meter housing/handlebar clamp (3).

NOTE

Make certain that speedometer harness and trip odometer
switch harness are positioned underneath the handlebar, and
indicator lamp module harness feeds over the top of the
handlebar.

If removed, push trip odometer reset switch through
speedometer housing/handlebar clamp and into tab square
in base of speedometer housing/handlebar clamp and
thread on the trip reset boot.

Hold speedometer (1) in place and mate speedometer
connector [39] halves.

NOTE

If necessary, lubricate gasket with alcohol or glass cleaner.

Press speedometer into speedometer housing/handlebar
clamp and secure with screws (5).

Install riser cover (9) and secure with two screws (8). Make
certain that handlebar control harnesses are not pinched
between handlebar riser and riser cover. Tighten screws
to 8-12 in-lbs (0.9-1.4 Nm).

Plug in main fuse. See

6-18 2009 Sportster Service: Electrical

6.9

SPEEDOMETER AND TACHOMETER: XR
MODELS

SPEEDOMETER REMOVAL

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

NOTE

The speedometer and tachometer have backlight bulbs that
cannot be replaced. If the bulb fails, replace the entire unit.

Unplug main fuse. See

Figure 6-23

. Remove reset switch boot (11).

Remove screws (6) and back cover (5).

Disconnect speedometer connector (8).

Push out the speedometer (2) with seal (3).

Inspect seal (3), speedometer connector (8), and wiring.
Repair or replace as required.

SPEEDOMETER INSTALLATION

See

Figure 6-23

. Install seal (3) on speedometer (2).

Orient face upright and press speedometer (2) into
instrument housing/bracket (4).

Install speedometer connector (8).

Attach trip odometer reset switch (10) into squared boss
on back cover (5) and secure with reset switch boot (11).

Place back cover over speedometer and tachometer while
positioning harness to avoid damage. Rotate speedometer
and tachometer as needed to align mounting holes and
install screws (6).

Plug in main fuse. See

2009 Sportster Service: Electrical 6-19

bushings which could damage caliper during vehicle
operation.

•

See

Figure 1-29

. It is further not required or recommended

to remove or loosen the caliper mounting pins (4).

•

It is not necessary or recommended to remove the rear
brake caliper from the caliper mounting bracket to replace
pads.

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Place motorcycle in an upright, level position.

NOTE

See

Figure 1-27

. As the piston is pushed back into the caliper,

fluid level may rise higher than the upper fluid level (3) in the
reservoir (1). You may have to remove fluid to allow for this.

Figure 1-27

. Remove rear master cylinder reservoir

cap (2).

sm01425

Rear brake master cylinder reservoir

Reservoir cap

Upper fluid level

Lower fluid level

Reservoir cover

Figure 1-27. Rear Brake Master Cylinder Reservoir: XL

Models

Press against the side of the brake caliper body to push
the outside brake pad (pad closest to caliper piston) back.
This pushes the caliper piston back into its bore.

NOTES

•

See

Figure 1-28

. When replacing rear brake pads, make

sure pad spring does not become dislodged and fall out.

If it does, you will have to reinstall it before installing new
pads.

•

The rear brake caliper does NOT use the same brake pad
set as the front left and front right (not present on all
models) calipers.

sm01432

Figure 1-28. Rear Caliper Pad Spring

See

Figure 1-29

. Remove pad pin plug (3).

Figure 1-30

. Loosen, but do not remove, brake pad

pin.

NOTE

Do not completely remove brake pad pin from caliper during
the next step. Completely removing pad pin at this time may
cause difficulty during assembly.

Once the piston has been fully retracted into its bore, pull
pad pin part way until inside pad drops free. Note the pad's
original orientation for replacement purposes.

1-28 2009 Sportster Service: Maintenance

sm03590

Rear brake caliper

Caliper mounting bracket

Pad pin plug

Caliper mounting pins

Figure 1-29. Rear Caliper Assembly

sm01434

Figure 1-30. Brake Pad Pin (Plug Removed)

Figure 1-31

. Install new inside brake pad (2) using

same orientation as pad previously removed. Make sure
front mounting tab (3) is seated in slot (6) in caliper
mounting bracket (5) and pad friction material faces brake
disc.

While holding new inside pad in place, pull pad pin out
and remove outside brake pad (1). Note the pad's original
orientation for replacement purposes.

Install new outside brake pad using the same orientation
as pad previously removed. Make sure front mounting tab
is seated in slot in caliper mounting bracket and pad friction
material faces brake disc.

10. Temporarily insert a 1/8-in. (3.175 mm) drill bit in caliper

pad pin hole to hold pads in place.

11. Inspect pad pin for grooving and wear. Measure pad pin

diameter in an unworn area, and then in the area of any
grooving or wear. If wear is more than 0.011 in. (0.28 mm),
replace pin.

12. Press brake pads firmly up against pad spring, remove

drill bit and install pad pin. Tighten to 131-173 in-lbs (14.8-
19.6 Nm).

NOTE

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

Figure 1-28

•

See

Figure 1-31

. Pad front mounting tabs (3) must be fully

seated in mounting bracket slot (6).

•

Pads must be pushed tight up against pad spring before
pad pin is installed.

13. See

Figure 1-29

. Install pad pin plug (3). Tighten to 18-25

in-lbs (2.0-2.9 Nm).

sm01435

Outside brake pad

Inside brake pad

Front mounting tab

Pad pin hole

Rear caliper mounting bracket

Slot

Figure 1-31. Rear Brake Pads

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)

14. Pump brake pedal to move piston out until it contacts

outside brake pad. Verify piston location against pad.

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: Maintenance 1-29

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

Figure 1-27

. Reservoir cover (5) may be removed

from rear brake master cylinder reservoir (1) to more easily
verify fluid level in reservoir.

15. See

Figure 1-27

. If desired, remove rear brake master

cylinder reservoir cover (5) by grasping cover and gently
pulling it straight away from reservoir (1).

16. Check brake fluid level in master cylinder reservoir. If

necessary, add HARLEY-DAVIDSON D.O.T. 4 BRAKE
FLUID to reservoir until fluid reaches upper fluid level (3).

17. Replace master cylinder reservoir cap (2). Replace

reservoir cover (5), if removed.

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)

18. Test brake system.

Turn ignition switch ON. Pump brake pedal to verify
operation of the rear brake lamp.

Test ride motorcycle at low speed. If the brakes feel
spongy, bleed the system. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

1-30 2009 Sportster Service: Maintenance

1.10

BRAKE PADS AND DISCS: XR MODELS

INSPECTION

Brake Pads

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

1.10 BRAKE PADS AND DISCS: XR MODELS, Brake Pad
Replacement: Front

Figure 1-32

. Replace brake pads if thickness (1) of brake

pad friction material (3) is worn to 0.040 in. (1.02 mm) or less.
Always replace both pads in a caliper as a set. See

1.10 BRAKE PADS AND DISCS: XR

MODELS, Brake Pad Replacement: Rear

When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage or leakage.

Brake Disc Thickness, Lateral Runout and
Warpage

The minimum brake disc (4) thickness is stamped on the side
of the disc. Replace disc if worn past minimum thickness or
badly scored.

Maximum brake disc lateral runout and warpage is 0.008 in.
(0.2 mm) when measured near the outside diameter.

•

To replace front brake disc(s), see

2.4 WHEELS, Front

Wheel

•

To replace rear brake disc, see

2.4 WHEELS, Rear Wheel

sm05127

Friction material thickness

Pad backing plate

Friction material

Brake disc

Figure 1-32. Brake Pad Inspection (front brake shown)

BRAKE PAD REPLACEMENT: FRONT

Removal

NOTES

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Cover handlebar switches with a shop towel before adding
brake fluid to front master cylinder reservoir. Spilling brake
fluid on handlebar switches may render them inoperative.

Position motorcycle so that front master cylinder reservoir
is level.

Figure 1-33

. Remove two screws (5), reservoir cover

(4), diaphragm plate (3) and diaphragm (2) from master
cylinder reservoir (1).

NOTE

As the pistons are pushed back into the caliper, fluid level may
rise higher than fluid level mark at about 1/4-in. (6.35 mm)
below top of reservoir. Remove fluid as necessary to prevent
overflow.

Wrap a shop towel around the master cylinder reservoir
to contain any brake fluid spills.