Harley Davidson Sportster Models 2009. Service Repair Manual — page 27

. Remove rear fender strut covers (21)

with attached turn signal assemblies (16) from rear fender
struts.

13. Remove screw (13), seat post (14) and flat washer (15)

to detach top of rear fender (1) from frame cross member
tab.

14. Carefully remove rear fender with attached tail/brake lamp

assembly from motorcycle.

15. See

Figure 2-233

. Depress latch on rear lighting power

connector [94] (3) and unplug connector from rear lighting
circuit board.

16. Remove screw with washer (5) and lift tail/brake lamp

base from fender.

17. Gently bend back ECM caddy latches on underside of

fender and lift caddy from top of fender.

sm01219

Rear turn signal stalk nut (2)

Forward fender support screw with washer (2)

Aft fender support screw with washer (2)

Forward fender support nut (2)

Aft fender support nut plate (2)

Wire retention bracket

Rear lighting wiring harness and conduit

Figure 2-237. Rear Fender, Strut Cover and Turn Signal

Lamp Assembly

INSTALLATION

NOTE

If a new fender is being installed, complete steps 1-7. Other-
wise proceed directly to step 8.

. Install license plate assembly on new

rear fender:

Remove three screws (3), three nuts (4) and one
washer (5) securing license plate bracket assembly
(2) and rear fender brace (25) to old fender (1).

Position assembly on new fender and secure with
screws, nuts and washer.

Align remaining holes in rear fender brace with aft
fender support screw holes in fender.

Tighten license plate bracket mounting screws to
20-25 in-lbs (2.3-2.8 Nm).

Carefully drill out pop rivets securing rear fender extension
(26) to old fender with a 1/4-in diameter drill bit. Rivet rear
fender extension to new fender.

2009 Sportster Service: Chassis 2-159

Carefully drill out pop rivets securing wire retention
brackets (28) to old fender with a 1/4-in diameter drill bit.
Rivet brackets to new fender.

Remove fender seat nut kit (24) from old fender and install
on new fender.

Place fender upside down on clean, soft towel or mat to
protect the finish. Clean inside area of fender where wiring
harness/conduit will be placed, with a mixture of alcohol
and water. Allow to air-dry thoroughly.

Position new wire harness and conduit inside fender at
the same approximate position where harness/conduit
assembly is located in old fender. Insert end of wiring
harness with 'D' plug through 'D' hole in front of fender.
Insert plug into hole.

Slide conduit toward 'D' plug as far as it will go. Insert other
end of wiring harness through tail lamp housing hole in
rear of fender. Remove adhesive tape backing from con-
duit and press conduit in place along right side curve of
fender.

Carefully install rear fender onto motorcycle. Align holes
in fender with those in struts. Temporarily install screws
(18, 20) through fender struts and fender to hold fender
in place. Route rear lighting harness connector [7B]
between frame cross member and top of oil tank. Plug
connector into socket [7A].

. Secure front of fender with screw (13),

washer (15) and seat post (14). Finger-tighten screw only,
at this time.

10. H-DSSS equipped models: Make sure antenna harness

feeds up between oil tank and fender on right side of
vehicle, and is not pinched between fender and frame
crossmember.

11. Remove screws from right side of fender that were tempor-

arily installed in step 8. Install right side rear fender strut
cover (21) with attached turn signal assembly to fender
strut. Push turn signal wiring harness through appropriate
hole in strut and fender. Install nut (22) onto turn signal
stalk (17) from inside fender. Finger-tighten only at this
time.

12. Secure fender to strut with screw (20), washer (19) and

nut (22) in forward mounting hole. Install screw (18),
washer (19) and nut plate (23) in aft mounting hole. Finger-
tighten screws only at this time.

13. Repeat steps 11. and 12. on left side of fender.

14. Now tighten all fender mounting hardware in the following

sequence:

Tighten screw (13) and seat post (14) to 96-156 in-
lbs (10.9-17.6 Nm).

Tighten turn signal stalk nuts to 132-216 in-lbs (14.9-
24.4 Nm).

Tighten screws (18, 20) to 132-216 in-lbs (14.9-24.4
Nm).

15. Install tail lamp base (11) to fender with screw (10) and

clip nut (12). Tighten screw to 45-48 in-lbs (5.1-5.4 Nm).

16. See

Figure 2-233

. Push 6-pin Amp connector [94] (3) and

left [18] (1) and right [19] (2) turn signal connectors through
access holes in tail lamp base and connect as shown.

17. See

Figure 2-236

. Snap ECM caddy (9) into place in top

of fender.

18. H-DSSS equipped models: Place security antenna (5)

into recess in ECM caddy with flat side of antenna facing
up and connector (6) facing right side of vehicle. Press
down gently on antenna until it snaps in place. Route
harness around right side of caddy and through harness
retainer (8).

19. Lower ECM (1) onto locating pins in ECM caddy with ECM

connector [78A] facing right side of vehicle. Press down
gently on ECM until it snaps in place. H-DSSS equipped
models: Make sure antenna harness is not pinched
underneath ECM.

20. Plug ECM connector [78B] (2) into ECM.

21. See

Figure 2-233

. Insert tail lamp connector [93] (4) in tail

lamp base socket as shown. See

. Screw tail

lamp socket assembly (9) into lens (7). Attach tail lamp
lens (7) to base (11) with two screws (6).

22. Plug in main fuse. See

Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)

23. Turn ignition switch ON and check rear lighting.

Make sure tail lamp is lit.

Depress turn signal switches and make sure both turn
signals are operating properly.

Operate front or rear brake and make sure brake lamp
illuminates.

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)

24. Install seat.

6.26 REAR LIGHTING CONVERTER MODULE: XL 1200N

2-160 2009 Sportster Service: Chassis

2.35

REAR FENDER AND LICENSE PLATE BRACKET:
XL 1200N

GENERAL

Unlike all other XL models, XL 1200N models sold in the
dometic market are equipped with a convertible side-mount
license plate bracket assembly. Incorporated into the bracket
is a license plate lamp module.

NOTE

Due to local regulations, this side mount license plate bracket
may not be offered in all markets.

The standard rear fender-mounted tail lamp and brake lamp
assembly common to all other XL models is not present on the
domestic XL 1200N. Instead, the rear turn signals also function
as tail lamps and brake lamps and are controlled by a rear
lighting converter module located under the seat.

For instructions on replacing the rear lighting converter module,
see

(DOMESTIC ONLY)

NOTES

•

XL 1200N models sold in the international market are
equipped with a center mounted license plate bracket that
incorporates a license plate lamp assembly.

•

XL 1200N models sold in the international market are not
equipped with a rear lighting converter module. Instead,
they incorporate discrete LED assemblies in the rear turn
signal housings for brake lamp, tail lamp and turn signal
functions.

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

Position motorcycle upright on suitable lift with rear wheel
elevated.

Remove rear wheel. See

2.4 WHEELS

Remove seat.

See

Figure 2-238

. 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 vehicles: Gently bend back antenna
latch (7) and lift security antenna (5) out of recess. Release
antenna harness from harness retainer (8) in ECM caddy.
Position antenna and harness out of the way.

See

Figure 2-239

. Unplug license plate lamp connector

(1) [40]. Unplug right rear lighting harness connector (3)
[19]. This connector is identified by a brown band (4) on
the harness near the connector. Unplug left rear lighting
harness connector (2) [18].

is03673

ECM

ECM connector [78B]

Connector latch

ECM latch (2)

Security antenna (H-DSSS equipped vehicles
only)

Antenna connector [209B] (H-DSSS equipped
vehicles only)

Antenna latch

Harness retainer

ECM caddy

Figure 2-238. Security Antenna (H-DSSS only) and ECM

Removal/Installation

sm01220

License plate lamp connector [40]

Left rear lighting harness connector [18]

Right rear lighting harness connector [19]

Brown band

Figure 2-239. Rear Lighting Harness Connectors

2009 Sportster Service: Chassis 2-161

Figure 2-240

. Carefully pull both rear lighting har-

nesses (2, 3) and license plate lamp harness (6) through
feed-through holes (4, 5) in rear fender.

10. Remove both rear lighting harnesses and license plate

lamp harness from fender harness clips (1).

11. See

Figure 2-241

. Remove left rear lighting harness (5)

from harness clips (2) on lower side of bracket on left side
of fender. Repeat this step for right side of fender.

12. See

. Remove rear turn signal stalk nuts (6)

from inside rear fender on both sides.

13. Remove forward fender support screw with washer (2)

and nut (4), and aft fender support screw with washer (3)
and nut plate (5) (domestic only) on both sides.

14. Remove screw with washer (10) and rear fender brace

(7).

15. HDI models: Remove license plate lamp module harness

from upper harness clips on bracket inside fender (left
side). Separate license plate bracket from rear fender
brace.

16. Remove rear fender strut covers (1) with attached turn

signal assemblies from rear fender struts. Carefully pull
turn signal wiring harnesses through holes in rear fender
and strut as each strut cover is removed.

sm01172

Harness bracket (2)

Right rear lighting harness

Left rear lighting harness

Right feed-through hole

Left feed-through hole

License plate lamp harness

Figure 2-240. Lighting Harnesses and Harness Brackets

(View from Inside Rear Fender): XL 1200N

sm01222

Upper license plate bracket harness clip (5)

Lower license plate bracket harness clip (3)

Harness channel

License plate lamp harness

Left rear lighting harness

Screw (2)

License plate lamp module

Figure 2-241. Removing/Installing License Plate Lamp

Module (Domestic Only)

sm03612

Rear fender strut cover

Forward fender support screw with washer (2)

Aft fender support screw with washer (2)

Forward fender support nut (2)

Aft fender support nut plate (2)

Rear turn signal stalk nut (2)

Rear fender brace

Fender seat nut kit (2)

ECM caddy

10. Screw with washer

Figure 2-242. Rear Fender, Strut Cover and Turn Signal

Lamp Assembly (Typical, Domestic Shown)

2-162 2009 Sportster Service: Chassis

17. Place a clean shop towel between each fender strut and

fender to protect paint.

18. Have an assistant hold rear fender in place. See

Figure 2-243

. Remove seat post (1), washer (2) and screw

(5). Remove rear fender from vehicle, being careful not to
damage paint. Lay rear fender on a soft, clean surface.

19. Domestic models: Remove convertible side mount

license plate bracket from rear fender.

Figure 2-241

. Remove license plate lamp module

harness from upper harness clips (1) and harness
channel (3) in license plate bracket. Remove two
screws (6) and license plate lamp module (7).

See

Figure 2-244

. Carefully drill out two pop rivets

(3) securing license plate bracket assembly (2) to left
side of fender.

20. See

. If rear fender is being replaced, do the

following:

Remove ECM caddy (9).

Remove fender seat nut kit (8).

Carefully drill out pop rivets securing rear fender
extension to old fender with a 1/4-in (6.35 mm) dia-
meter drill bit.

Set caddy, nut kit and fender extension aside for now.

sm03611

Seat post

Washer

Fender mounting tab

Grommet

Screw

Figure 2-243. Seat Post/Rear Fender Mount Hardware

sm01223

Rear fender

License plate bracket assembly

Pop rivet (2)

Figure 2-244. Removing/Installing License Plate Bracket

Assembly (Domestic Only)

ASSEMBLY AND INSTALLATION

See

. If new rear fender is being installed, do

the following:

Install ECM caddy (9).

Install fender seat nut kit (8).

Rivet rear fender extension to fender.

Domestic models: Install convertible side mount license
plate bracket on fender.

See

Figure 2-244

. Position license plate bracket

assembly (2) against inside of rear fender (1) on left
side. Line up holes in bracket with holes in fender and
secure bracket to fender with two new pop rivets (3).

Figure 2-241

. Install license plate lamp module

(7) on to license plate bracket. Secure with two screws
(6). Feed license plate lamp harness (4) up through
harness channel (3). Insert harness into upper license
plate bracket harness clips (1).

Place clean shop towels over fender struts. With the aid
of an assistant, carefully install rear fender onto vehicle.

Figure 2-243

. With assistant holding rear fender in

place, install screw (5) through fender and frame tab.
Install washer (2) on screw. Thread seat post (1) onto
screw. Tighten seat post only finger tight at this time.

H-DSSS equipped vehicles: Make sure antenna harness
feeds up between oil tank and fender on right side of
vehicle. and is not pinched between fender and frame
crossmember.

Remove shop towels from fender struts.

. Install fender strut covers (1) with

attached turn signal lamp assemblies. Carefully feed each
turn signal harness through appropriate hole in fender
strut and fender as you install each strut cover.

2009 Sportster Service: Chassis 2-163

Thread nut (6) onto each rear turn signal stalk finger-tight.
Install two forward fender support screws with washers
(2). Thread nut (4) onto each screw finger-tight.

HDI models: hook tab of license plate bracket into slot in
rear fender brace.

10. Place rear fender brace (7) in position under fender and

secure with screw and washer (10) finger-tight. Install two
aft fender support screws with washers (3).

HDI models: thread each mounting screw through
rear fender brace, into threaded inserts in license
plate bracket. Install finger-tight. Make sure threaded
inserts in license plate bracket fit into holes in rear
fender brace.

Domestic models: see

Figure 2-245

. Install nut plate

(2) on each mounting screw (5) finger-tight.

NOTE

Domestic models: see

Figure 2-245

. Make certain that tab

(3) on each nut plate (2) fits into slot (4) in fender brace (1)
when securing nut plate with rearmost fender mounting screw
(5).

sm01224

Rear fender brace

Nut plate (2)

Tab

Slot

Mounting screw (2)

Figure 2-245. Rear Fender Nut Plate (Domestic Only)

11. Now tighten all fender mounting hardware in the following

sequence:

Figure 2-243

. Tighten screw (5) and seat post

(1) to 96-156 in-lbs (10.9-17.6 Nm).

See

1.16 REAR BELT DEFLECTION

. Tighten left and right turn signal

stalk nuts (6) to 132-216 in-lbs (14.9-24.4 Nm).

Tighten forward and aft fender support screws (2, 3)
on both sides of fender to 132-216 in-lbs (14.9-24.4
Nm).

Tighten rear fender brace screw (10) to 20-25 in-lbs
(2.3-2.8 Nm).

12. See

Figure 2-240

. Install left rear lighting harness (3) and

license plate lamp harness (6) into fender harness clip (1)
on left side of fender. Install right rear lighting harness (2)
into fender harness clip on right side of fender.

13. Carefully feed both rear lighting harnesses and license

plate lamp harness through feed-through holes (4, 5) in
rear fender.

14. See

Figure 2-239

. Plug in license plate lamp connector

(1) [40]. Plug in left rear lighting harness connector (2)
[18].

15. Plug in right rear lighting harness connector (3) [19]. This

connector is identified by a brown band (4) on the harness
near the connector.

16. H-DSSS equipped vehicles: See

Figure 2-238

. Gently

bend back antenna latch (7) and position security antenna
(5) in recess in ECM caddy (9). Release latch. Position
antenna harness in harness retainer (8).

17. See

Figure 2-238

. Gently bend back ECM latches (4) and

install ECM into locating pins on caddy with connector
[78A] on ECM body facing right side of vehicle.

18. Plug harness connector [78B] (2) into ECM. Tug gently

on connector to make sure connector latch (3) has locked
in position properly and cannot come loose.

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)

19. Install seat.

20. Install rear wheel. See

2.4 WHEELS

. Make certain rear

wheel is properly aligned and rear drive belt is properly
tensioned. See

21. Plug in main fuse. See

Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)

22. Turn ignition switch ON. Verify all rear lighting is operating

properly: license plate lamp, tail lamps, brake lamps and
turn signals.

2-164 2009 Sportster Service: Chassis

23. Start engine to verify proper ECM function. Turn ignition

switch OFF.

24. Remove vehicle from lift.

2009 Sportster Service: Chassis 2-165

2.36

REAR FENDER: XR MODELS

REMOVAL

Remove rider's seat and passenger pillion.

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 2-246

. Remove three bolts and washers (1).

Remove two bolts (2) and retainers (3). Lift tail section (4)
off from motorcycle.

Remove screw (5). Rotate inner fender (6) down and
release tabs (7) from notches in frame.

Disconnect ECM connector and remove inner fender and
ECM as an assembly. Remove ECM from inner fender if
necessary.

INSTALLATION

See

Figure 2-246

. If removed, install passenger pillion

retainer post (9). Tighten screw (8) to 36-60 in-lbs (4.1-
6.8 Nm).

If removed, install ECM on inner fender.

While holding inner fender/ECM assembly in place, con-
nect ECM connector.

Ensure tabs (7) are located in notches in frame and secure
inner fender with screw (5). Tighten to 72-120 in-lbs (8.1-
13.6 Nm).

NOTE

Washers and retainers (3) are installed with shoulder down.

Install tail section (4) and secure with bolts, washers, and
seat retainers. Tighten bolts to 72-120 in-lbs (8.1-13.6
Nm).

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)

Install passenger pillion and rider's seat.

Install main fuse.

sm05333

Bolt and washer, short (3)

Bolt, long (2)

Seat retainer (2)

Tail section

Screw, inner fender

Inner fender

Tabs

Pillion retainer post screw

Passenger pillion retainer post

Figure 2-246. Rear Fender: XR Models

2-166 2009 Sportster Service: Chassis

2.37

JIFFY STAND

GENERAL

See

. The vehicle is equipped with a jiffy stand

(or side stand) that locks when placed in the full forward posi-
tion (down) with the full weight of the vehicle resting on it.

The jiffy stand locks when placed in the full forward (down)
position with vehicle weight on it. If the jiffy stand is not
in the full forward (down) position with vehicle weight on
it, the vehicle can fall over which could result in death or
serious injury. (00006a)

Always park motorcycle on a level, firm surface. An
unbalanced motorcycle can fall over, which could result
in death or serious injury. (00039a)

Be sure jiffy stand is fully retracted before riding. If jiffy
stand is not fully retracted, it can contact the road surface
causing a loss of vehicle control, which could result in
death or serious injury. (00007a)

sm01226

Clevis pin

Pretzel clip

Bushing (2)

Jiffy stand leg

Rubber bumper

Spring

Jiffy stand yoke

Figure 2-247. Jiffy Stand (Retracted Position) (Typical)

JIFFY STAND INTERLOCK:
INTERNATIONAL MODELS

Some international models are equipped with a jiffy stand
interlock feature.

If the rider attempts to start the engine or pushes the starter
button while the transmission is in gear and the jiffy stand is
down, then the jiffy stand interlock system will not permit the
engine to run. The message "SidE StAnd" will scroll across

the odometer to indicate this to the rider. Raising the jiffy stand
(or putting the transmission in neutral) will permit the engine
to run and clear the message.

If the jiffy stand falls out of the fully retracted position while
riding at speeds greater than 10 mph (15 km/h), then the jiffy
stand interlock system will maintain engine operation and alert
the rider about this by illuminating the indicators (flash twice)
and scroll the message "SidE StAnd" across the odometer.
The message will remain until the system detects the jiffy stand
in the fully retracted position again. The rider may continue to
operate the vehicle while in this mode.

The rider may clear the text messages at any time by pressing
the function switch once while the vehicle is powered up.

NOTE

If the operation of raising the jiffy stand and putting the trans-
mission in gear is rapidly executed, the jiffy stand bouncing off
the frame could cause the jiffy stand interlock system to activate
and stop the engine.

REMOVAL

Block motorcycle under frame so that motorcycle is
securely resting upright and jiffy stand may be moved
through its full range of travel.

. Remove rubber bumper (5) from frame

to permit further retraction of jiffy stand leg (4). Additional
spring tension relief allows for easier spring removal.

Figure 2-248

. Place jiffy stand leg in retracted position.

Remove and discard pretzel clip (3).

Wear safety glasses or goggles when removing or
installing spring. Spring tension can cause spring,
attached components and/or hand tools to fly out which
could result in death or serious injury. (00477c)

While firmly holding jiffy stand leg (5) in fully retracted
position, withdraw clevis pin (1) until it disengages from
upper pivot hole of jiffy stand yoke (4).

Detach spring (6) from anchor pin (7) using pliers. Unhook
other end of spring from jiffy stand leg.

Remove clevis pin from lower pivot hole of jiffy stand yoke.
Remove jiffy stand leg. Remove upper and lower bushings
(2).

CLEANING AND LUBRICATION

Clean and lubricate jiffy stand assembly every 5000 miles (8000
km). Proceed as follows:

2.37 JIFFY STAND, Removal

Figure 2-248

. See

above to remove jiffy stand from motorcycle frame.

Thoroughly clean all jiffy stand components, including
frame-mounted anchor pin and jiffy stand yoke (4).

Apply a small amount of wheel bearing grease to pivot
holes of jiffy stand leg (5) and yoke, groove of anchor pin
and O.D. of clevis pin (1).

2.37 JIFFY STAND, Installation

2009 Sportster Service: Chassis 2-167

See

to install jiffy stand

to motorcycle frame.

INSTALLATION

Clean and lubricate jiffy stand components according to
procedure listed in

2.37 JIFFY STAND, Cleaning and

Lubrication

above.

NOTE

See

Figure 2-247

. When installing jiffy stand spring (6), make

sure open ends of spring hooks face inward toward centerline
of vehicle, as shown in the figure.

Figure 2-248

. Hook either end of spring (6) into spring

mounting hole on jiffy stand leg (5). Install other end of
spring over frame mounted anchor pin (7).

Install bushing (2) onto clevis pin (1) with shoulder of
bushing facing head of clevis pin.

While holding end of spring in groove of anchor pin and
holding jiffy stand leg in its retracted position, place pivot
end of jiffy stand leg into yoke (4) on motorcycle frame
(refer to

Table 2-27

. for correct clevis pin application).

Insert clevis pin (1) up through lower pivot hole of yoke
and halfway into pivot hole of jiffy stand leg.

See

. Lift jiffy stand leg (4) upward, aligning

pivot hole of jiffy stand leg with slotted upper hole of yoke
(7). Push clevis pin through upper hole in yoke. Make
certain that shank of lower bushing (3) fits inside lower
pivot hole in yoke.

Install upper bushing with shoulder facing up, over end of
clevis pin and against upper surface of yoke. Insert new
pretzel clip (2) through hole in end of clevis pin.

NOTE

See

Figure 2-249

. Make sure the loop of the pretzel clip snaps

over the end of the clevis pin.

. Press rubber bumper (5) onto mounting

stud on motorcycle frame.

Extend and retract jiffy stand leg several times to check
for proper operation. In retracted position (up), jiffy stand
leg should be securely seated against frame-mounted
rubber bumper.

Place jiffy stand in its full forward position (down). Carefully
remove support blocking from beneath motorcycle frame.
Rest motorcycle on jiffy stand.

Table 2-27. Clevis Pin Application

OVERALL

LENGTH (IN/MM)

PIN COLOR

MODEL

2.64/67.1

Black

XL 883L

2.72/69.1

Silver

All except XL 883L

sm02205

Clevis pin

Bushing (2)

Pretzel clip

Jiffy stand yoke

Jiffy stand leg

Spring

Anchor pin

Figure 2-248. Jiffy Stand

sm01227

Figure 2-249. Pretzel Clip

2-168 2009 Sportster Service: Chassis

2.38

SEAT: XL MODELS

GENERAL

The seat is attached to the vehicle at three points.

See

Figure 2-250

. The tongue (1) fits under the rear fuel

tank bracket.

The keyhole (2) locks into the seat post (See

Figure 2-251

. The mounting bracket (2) bolts to the

seat with two screws (5) and lock washers (6), and
attaches to a seat nut (4) in the rear fender with a screw
(1).

SEAT REMOVAL: XL MODELS

. Remove screw (1) to detach seat from

rear fender.

Slide seat forward and lift up slightly to detach keyhole
bracket from seat post. Then slide seat rearward to detach
seat tongue from rear fuel tank bracket.

See

Figure 2-250

. Verify that tongue (1) and keyhole

bracket (2) are tightly secured to seat bottom and that no
rivets are loose or missing.

. If two-up seat (8), inspect passenger

strap (9) for damage or excessive wear.

NOTE

The passenger strap is not sold separately. If it is damaged,
excessively worn or otherwise unusable, the entire seat
assembly must be replaced.

sm03347

Tongue

Keyhole bracket

Passenger strap

Figure 2-250. Seat

sm03348

Figure 2-251. Seat Post: Sportster XL Models

SEAT INSTALLATION: XL MODELS

. Position seat on frame with mounting

bracket at rear.

Slide seat forward until the tongue fits snugly under rear
fuel tank bracket.

See

Figure 2-251

. Push seat forward, engage keyhole

onto seat post, then pull seat back slightly.

See

. Install seat mounting screw with captive

washer (1) to fasten seat mounting bracket to top of rear
fender. Mounting bracket of solo seat uses forward hole
in rear fender; dual seat uses rearward hole.

Pull up on seat to verify that it is locked in place.

Tighten seat mounting screw.

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)

Pull up on seat again to verify that it is properly secured
at all three points.

2009 Sportster Service: Chassis 2-169

sm04208

Lock washer

Seat mounting screw with captive washer

Mounting bracket

Seat assembly, solo (typical)

Seat assembly, two-up (typical)

Retaining clip

Seat nut

Passenger strap (not sold separately)

Screw (2)

Figure 2-252. Seat Assembly: Sportster XL Models

2-170 2009 Sportster Service: Chassis

2.39

SEAT: XR MODELS

SEAT REMOVAL: XR 1200 MODEL

Figure 2-253

. Reach under front end of tail section

and press the two seat tabs inward.

Pull front of seat upward to disengage seat from the front
end of the tail section.

Pull seat forward over fuel tank.

NOTES

•

When removing the seat, verify that the mounting bracket
under the seat is tightly secured to the seat bottom and
that no rivets are loose or missing. Inspect passenger
strap for damage or excessive wear.

•

The passenger strap is not sold separately. If it is dam-
aged, excessively worn, or otherwise unusable, the entire
seat must be replaced.

om01260

Figure 2-253. Front Seat Tabs (Under Tail Section): XR

1200 Model

SEAT INSTALLATION: XR 1200 MODEL

See

Figure 2-254

. Place rear of seat into tail section,

aligning the guides in the seat bracket with the two seat
posts.

Push down on front of seat until the two tabs engage the
front end of tail section.

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)

om01259

Seat

Seat tabs

Seat posts

Passenger pillion

Pillion tabs

Pillion seat post

Figure 2-254. Seat and Pillion: XR 1200 Model

PASSENGER PILLION: XR 1200 MODEL

Removal

Figure 2-255

. Lift the rear of pillion to disengage

grommet from the seat post.

Pull pillion out from tail section.

Installation

See

Figure 2-255

. Insert pillion into trunk, aligning tabs on

pillion with the slots in the trunk.

Push down firmly on rear of pillion until grommet fully
engages the seat post.

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)

2009 Sportster Service: Chassis 2-171

om01277

Pillion

Tabs

Seat post

Figure 2-255. Passenger Pillion: XR 1200 Model

2-172 2009 Sportster Service: Chassis

2.40

RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS

RIGHT FOOTREST AND REAR BRAKE
PEDAL ASSEMBLY

Removal

Remove front muffler. See

4.15 EXHAUST SYSTEM: XL

MODELS

See

. Remove retaining ring (3), clevis pin

(5), footrest (1) and spring washer (2). Discard retaining
ring.

Remove brake rod (7) from brake pedal (8) and master
cylinder bell crank (19).

Remove retaining ring (26), screw (11) and clevis (4). Slide
brake pedal (8) off clevis. Discard retaining ring.

Remove two screws (9) and right rider footrest/brake pedal
support bracket (10) from frame (12).

Installation

. Mount right rider footrest/brake pedal

support bracket (10) to frame (12) with two screws (9).
Tighten to 45-50 ft-lbs (61-68 Nm).

Slide brake pedal (8) onto clevis (4). Mount clevis on right
rider 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 (26) on end of clevis.

Install footrest (1) on clevis with spring washer (2). 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 (3).

Apply two drops of LOCTITE THREADLOCKER 243 (blue)
to threads of both brake rod ball stud screws.

Thread one end of brake rod (7) into master cylinder bell
crank (19). Tighten to 120-180 in-lbs (13.6-20.4 Nm).

Thread other end of brake rod into brake pedal. Tighten
to 120-180 in-lbs (13.6-20.4 Nm).

Install front muffler. See

4.15 EXHAUST SYSTEM: XL

MODELS

LEFT FOOTREST AND SHIFT LEVER
ASSEMBLY

Removal

. Remove retaining ring (15), clevis pin

(17), footrest (18) and spring washer (16). Discard
retaining ring.

Remove two screws (14) and left rider footrest support
bracket (13) from frame (12).

Remove screw (27) and shifter peg (25).

Remove pinch screw (22) and washer (23). Remove shift
lever assembly (24) and rubber washer (21).

Installation

See

. Install rubber washer (21) and shift

lever (24) on transmission shift lever shaft. Secure with
washer (23) and pinch screw (22). Tighten to 16-20 ft-lbs
(21.7-27.1 Nm).

If re-using shifter peg screw (27), 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.

Install shifter peg (25) and secure with screw (27). Tighten
screw to 96-144 in-lbs (10.9-16.3 Nm)

Attach rider footrest support bracket (13) to frame (12)
with two screws (14). Tighten to 45-50 ft-lbs (61-68 Nm).

Install footrest (18) on footrest support bracket with spring
washer (16). Make sure spring washer is positioned inside
support bracket mounting boss with the square edge
toward the inside. Align holes and push clevis pin (17)
from top down through hole in support bracket. Secure
with new retaining ring (15).

2009 Sportster Service: Chassis 2-173

sm02206

15.

Retaining ring

Footrest

16.

Spring washer

17.

Clevis pin

Retaining ring

18.

Rider footrest clevis

Footrest

19.

Bell crank

Clevis pin

20.

Bushing

Rear brake master cylinder and bracket assembly

21.

Rubber washer

Rear brake rod assembly

22.

Rear brake pedal

Pinch screw

23.

Washer

Screw (2)

10.

24.

Right rider footrest/brake pedal support bracket

Shift lever

25.

11.

Shifter peg

Screw

12.

26.

Frame

Retaining ring

27.

13.

Screw, shifter peg

Left rider footrest support bracket

14. Screw (2)

Figure 2-256. Mid-Mount Controls: Rider Footrests/Foot Controls