Harley Davidson Sportster Models 2009. Service Repair Manual — page 61

3.15 TOP END OVERHAUL: DISASSEMBLY,

3-72 2009 Sportster Service: Engine

3.17

BOTTOM END OVERHAUL: DISASSEMBLY

GENERAL

This section describes disassembling the bottom end of the
engine. If engine overhaul requires disassembly of crankcases,
remove engine from vehicle as described in

3.12 REMOVING

ENGINE FROM CHASSIS

. Then disassemble top end of

engine. See

Cylinder Heads

and

3.15 TOP END OVERHAUL: DISAS-

SEMBLY, Cylinder and Piston

Thoroughly clean area around gearcase cover and tappets.
Blow loose dirt from crankcase with low pressure compressed
air.

The oil pump design and function differs between XL and XR
models. See

3.8 ENGINE LUBRICATION SYSTEM

for more

information.

TAPPETS

CASE COVER AND CAM GEARS, Assembly and Install-
ation

Figure 3-68

. Remove screw (1).

Remove anti-rotation device (2). Tag anti-rotation device
for location (front/rear cylinder) as it is removed.

Remove tappet (3). Tag tappet for location (front/rear cyl-
inder) and function (intake/exhaust) as it is removed. This
will simplify installation.

Repeat previous steps for other cylinder.

Place tappets in clean plastic bags to keep out dust, dirt
and debris.

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Screw (2)

Anti-rotation device (2)

Tappet (4)

Right crankcase

Figure 3-68. Tappet Removal

OIL PUMP: XL MODELS

Remove oil pump feed and return hoses. Mark hoses for
later installation. Discard hose clamps.

See

Figure 3-69

. Carefully remove two screws (2) that

secure pump to crankcase. Pump will drop with screws
removed. Discard mounting gasket.

If oil pump requires repair, see

3.24 OIL PUMP: XL

MODELS

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Oil pump

Screw w/ washer (2)

Screw, Torx (2)

Gasket

Figure 3-69. Oil Pump: XL Models

GEARCASE COVER AND CAM GEARS: XL
MODELS

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)

Remove any parts that will interfere with gearcase disas-
sembly (i.e., exhaust pipe, footrest, air cleaner, brake
pedal, etc.).

Check for minimum cam gear end play; see

3.20 GEAR-

. Record readings.

2009 Sportster Service: Engine 3-73

Figure 3-70

. Place a pan under gearcase to collect

oil. Remove cover screws (6). Carefully remove gearcase
cover. Discard old gasket (9).

NOTE

If cover does not come loose on removal of screws, tap lightly
with a rawhide hammer. Never pry cover off.

Remove cam gears (1, 2, 3, and 4). Carefully mark each
component for installation reference.

NOTE

Nut (11) is secured by Loctite-262 on the nut threads.

Remove nut (11). Slide pinion gear (5) and oil pump drive
gear (12) off pinion shaft.

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11.

Nut

Rear exhaust cam gear

12.

Rear intake cam gear

Oil pump drive gear

13.

Cam gear bushing (4)

Front intake cam gear

14.

Front exhaust cam gear

Rear exhaust cam gear bushing

15.

Rear intake cam gear bushing

Pinion gear

16.

Screw (11)

Pinion shaft bushing

17.

Gearcase cover

Front intake cam gear bushing

18.

Front exhaust cam gear bushing

T-key

19.

Cover plate

Gearcase cover gasket

10.

20.

Right crankcase

Screw (2)

Figure 3-70. Gearcase and Valve Train Components: XL Models

OIL PUMP HOUSING/GEARCASE COVER
AND CAM GEARS: XR MODELS

The oil pump on XR models is integrated into the gearcase
cover. The oil pump rotors can be removed with the gearcase
cover in place if necessary however, it is not necessary to
remove the oil pump rotors to remove the gearcase cover.

AND CAM GEARS, Assembly and Installation

3-74 2009 Sportster Service: Engine

Remove any parts that will interfere with gearcase disas-
sembly (i.e., exhaust pipe, footrest, air cleaner, brake
pedal, etc.).

Remove inner rocker cover to remove valve spring pres-
sure from camshafts. See

3.15 TOP END OVERHAUL:

DISASSEMBLY, General

Check cam gear end play; see

3.20 GEARCASE COVER

. Record

readings.

Place a pan under gearcase to collect oil.

SYSTEM: XR MODELS, Oil Pump Lines

Figure 3-71

. Remove nine fasteners (1) and remove

cover (2).

See

Figure 3-72

. Remove rigid lines (1) and vent hose (2)

from gearcase cover. See

3.14 PRECISION COOLING

. Mark lines and

hoses for later installation. Discard hose clamps.

Remove two check valve housing screws (3).

Remove six screws (4) and remove oil pump cover (5).
Discard o-rings.

Remove three fasteners (6). Loosely install oil pump cover
to prevent rotors from falling out unexpectedly.

NOTE

Never pry gearcase cover off. If gearcase cover is difficult to
remove, tap lightly with a rawhide hammer.

10. Carefully remove gearcase cover. Discard old gasket.

NOTE

If oil pump requires repair, see

3.25 OIL PUMP: XR MODELS

11. See

Figure 3-73

. Remove cam gears (1, 2, 3, and 4).

Carefully mark each component to verify correct installa-
tion.

NOTE

Nut (5) is secured by Loctite-262.

12. Remove nut (5). Slide pinion gear (6) and spacer (7) off

pinion shaft.

13. Remove oil pump cover. Mark rotors with a permanent

marker to identify outer surfaces. Remove rotors from
housing.

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Fastener (9)

Cover

Figure 3-71. Oil Pump Cover: XR Models

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Rigid lines (4)

Vent hose

Check valve screws (2)

Oil pump cover screw (6)

Oil pump cover

Gearcase cover fastener (3)

Figure 3-72. Gearcase Cover and Oil Pump: XR Models

5.5 PRIMARY DRIVE AND CLUTCH: XL MODELS

2009 Sportster Service: Engine 3-75

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Rear exhaust cam gear

Rear intake cam gear

Front intake cam gear

Front exhaust cam gear

Nut

Pinion gear

Spacer

Figure 3-73. Cam Gears: XR Models

CRANKCASE

Remove clutch and primary drive components. See

Remove starter motor. See

6.13 STARTER

Mount crankcase assembly in engine stand. Position
crankcase so that it is tilted at a 45° angle, right side down.

Do not rotate right crankcase half in engine stand such
that flywheel sprocket shaft is facing down. The flywheel
assembly can fall out, resulting in parts damage or mod-
erate injury. (00553b)

NOTE

See

Figure 3-74

. Crankcase assembly has 17 fasteners; 15

inserted from left side and two inserted from right side.

See

Figure 3-74

. Remove 15 crankcase fasteners (eleven

long and four short) from left side of crankcase assembly.

sm03405

Short fastener

Left side

Right side

XR Models: double-headed bolt

Indicates crankcase fastener locations

Figure 3-74. Crankcase Fasteners

Remove two fasteners from right side of crankcase
assembly.

Tap crankcase gently with rawhide mallet to loosen and
separate the halves. See

Figure 3-75

. Remove left

crankcase assembly with transmission.

NOTE

Flywheel assembly slides off left main bearing by hand. No
tools are required for this operation.

Figure 3-76

. Remove the flywheel assembly from

right crankcase.

5.10 TRANSMISSION REMOVAL AND DISASSEMBLY

3-76 2009 Sportster Service: Engine

Remove transmission assembly from left crankcase. See

sm01506

Figure 3-75. Separating Crankcase Halves

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Figure 3-76. Removing Flywheels from Right Crankcase

Removing Piston Oil Jets

Figure 3-77

. Remove two TORX screws (3) from each

piston oil jet assembly (2) to free piston oil jets from right
crankcase (1).

Remove piston oil jets and gaskets (4) from right crank-
case. Discard gaskets.

XR Models: Remove three screws (6) and oil deflector
plate (5).

sm01596

Right crankcase

Piston oil jet (2)

Screw (4)

Gasket (2)

Oil deflector plate (XR models only)

Screw (3) (XR models only)

Figure 3-77. Piston Oil Jet Assemblies

Removing Cylinder Base Studs

If cylinder base studs require replacement, proceed as follows.

Thread a 3/8"-16 nut onto cylinder base stud.

Thread a second nut onto stud until it contacts the first
nut.

Tighten nuts against each other.

Placing wrench on first (lower) nut installed, remove stud
from cylinder deck.

Loosen nuts and remove from cylinder base stud.

2009 Sportster Service: Engine 3-77

3.18

BOTTOM END OVERHAUL: ASSEMBLY

CRANKCASE

TOOL NAME

PART NUMBER

GEAR DETENT ASSEMBLY AID

B-45520

CRANKCASE BEARING
REMOVER/INSTALLER

B-45655

SPROCKET SHAFT SEAL/SPACER
INSTALLER

B-45676-A

CRANKSHAFT GUIDE TOOL

HD-42326-B

SPROCKET SHAFT BEARING/SEAL
INSTALLATION TOOL

HD-42579-A

CRANKCASE BEARING
REMOVER/INSTALLER BASE

HD-42720-2

TRANSMISSION SHAFT RETAINING
RING PLIERS

J-5586-A

Installing Piston Oil Jets

NOTES

•

Gaskets that are missing, distorted, pinched or otherwise
damaged will result in either oil leakage or low oil pressure.

•

Figure 3-78

. Gasket (4) is part of piston oil jet (2)

assembly and is not sold separately.

See

Figure 3-78

. With oil jet pointed upward, install new

piston oil jet assemblies (2) with gaskets (4) in right
crankcase.

Apply Loctite Low Strength Threadlocker 222 (purple) to
threads of TORX screws (3) and screws (6).

Install TORX screws to secure piston oil jet assembly to
crankcase. Tighten to 25-35 in-lbs (2.8-4.0 Nm).

XR Models: Install oil deflector plate (5) using three
screws (6). Tighten screws to 25-35 in-lbs (2.8-3.9 Nm)

sm01596

Right crankcase

Piston oil jet (2)

Screw (4)

Gasket (2)

Oil deflector plate (XR models only)

Screw (3) (XR models only)

Figure 3-78. Piston Oil Jet Assemblies

Installing Pinion Shaft Bearings

Figure 3-79

and

Figure 3-80

. Lubricate pinion shaft

and pinion shaft bearing with clean Harley-Davidson
20W50 engine oil.

Slip bearing on pinion shaft.

Using TRANSMISSION SHAFT RETAINING RING
PLIERS (Part No. J-5586-A), install new retaining ring
(10) in groove of pinion shaft bearing inner race. Make
sure retaining ring is fully seated in groove.

3-78 2009 Sportster Service: Engine

sm01500

Figure 3-79. Installing Pinion Shaft Bearing and Retaining

Ring

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Retaining ring

Sprocket shaft spacer

Retaining ring

Connecting rod and flywheel assembly

Pinion shaft bearing

Left main oil seal

10.

Thrust washer

Retaining ring

11.

Outer bearing race

Left crankcase

12.

Left main bearing

Right crankcase

Figure 3-80. Crankcase and Flywheel Assembly (typical; XL model shown)

5.15 TRANSMISSION INSTALLATION

2009 Sportster Service: Engine 3-79

Installing Left Main Bearing

NOTE

When installing the left main bearing, the bearing presses from
the inside of the left crankcase toward the outside. A shoulder
is incorporated into the left crankcase which allows the bearing
to be installed in one direction only.

See

Figure 3-81

. Using CRANKCASE BEARING

REMOVER/INSTALLER (Part No. B-45655) and
CRANKCASE BEARING REMOVER/INSTALLER
BASE (Part No. HD-42720-2), press left main bearing into
the left crankcase.

Place support tube (1) on press bed with recessed
cup end facing up.

With the inboard side of the left crankcase (2) facing
upward, position crankshaft bearing bore (3) over
support tube.

Place left main bearing (4) over bearing bore. Insert
pilot/driver (5) through left main bearing, through
crankshaft bearing bore and into support tube.

Apply pressure with press ram (6) until left main
bearing bottoms out in bearing bore.

See

Figure 3-82

. See

Figure 3-80

. Install new retaining

ring (7) from the inside of the left crankcase.

sm01502

Support tube (HD-42720-2)

Left crankcase

Crankshaft bearing bore

Left main bearing

Pilot/driver (B-45655)

Press ram

Figure 3-81. Installing Left Main Bearing in Crankcase

Assembling Crankcase Halves

If not already done, install transmission assembly in left
crankcase. See

NOTE

Figure 3-83

. The Gear Detent Assembly Aid is used to

move the gear detent lever clear of the shifter drum for
assembly purposes.

Figure 3-83

. Retract detent assembly in right case

half and install GEAR DETENT ASSEMBLY AID (Part
No. B-45520) until it has bottomed in right case half.

sm01503

Figure 3-82. Installing Left Main Bearing Retaining Ring

sm03417

Detent assembly

Detent assembly aid

Figure 3-83. Using Gear Detent Assembly Aid (Part No.

B-45520)

Shift transmission to 1st gear.

3-80 2009 Sportster Service: Engine

Lubricate left main bearing with clean Harley-Davidson
20W-50 engine oil.

Assemble crankcase halves together.

Figure 3-84

. Install flywheel assembly in right

crankcase. Slide pinion shaft through outer race in
right crankcase.

Slide CRANKSHAFT GUIDE TOOL (Part No. HD-
42326-B) onto flywheel sprocket shaft.

Apply a thin coat of GRAY HIGH-PERFORMANCE
SEALANT (Part No. 99650-02) to crankcase joint
faces.

Figure 3-85

. Carefully fit crankcases together.

NOTE

Figure 3-86

. XR models have a double-ended bolt in

position 8 used to secure the front cylinder head oil return
line.

Figure 3-86

. Apply a few drops of LOCTITE 271

(red) to last few threads of each crankcase fastener
and install fasteners (thirteen long and four short) in
crankcase assembly, in locations shown.

Tighten fasteners to 15-19 ft-lbs (20.3-25.8 Nm) in
the sequence shown in

Figure 3-86

Remove transmission gear detent assembly aid.

sm01505

Figure 3-84. Installing Flywheels in Right Crankcase

sm04381

Figure 3-85. Assembling Crankcases with Crankshaft Guide

Tool (Part No. HD-42326-B)

2009 Sportster Service: Engine 3-81

sm01380a

Figure 3-86. Crankcase Fastener Torque Sequence (* - Short Fasteners; ** - Double-ended Bolt: XR Models)

See

Figure 3-87

and

Figure 3-88

. Install spacer in I.D. of

new seal. With the open (lipped) side of seal facing out-
ward, center seal/spacer assembly over bearing bore.

sm01507

Figure 3-87. Open (Lipped) Side of Seal Faces Out

sm01508

Figure 3-88. Install Spacer and Seal

NOTE

Do not remove the spacer after installation or the new seal will
have to be discarded and the procedure repeated.

See

Figure 3-89

. Install bearing seal and spacer.

Center seal/spacer driver (2) over seal, so that the
sleeve (smaller O.D.) seats between seal wall and
garter spring.

Assemble SPROCKET SHAFT BEARING/SEAL
INSTALLATION TOOL (Part No. HD-42579-A) (1)
and SPROCKET SHAFT SEAL/SPACER
INSTALLER (Part No. B-45676-A) onto sprocket shaft.

Rotate handle clockwise until the spacer makes con-
tact with the bearing. Remove tool from sprocket
shaft.

3-82 2009 Sportster Service: Engine

sm01509

Bearing/seal installer (Part No. HD-42579-A)

Seal/spacer installer (Part No. B-45676-A)

Figure 3-89. Install Bearing Seal/Spacer

See

Figure 3-80

. Install retaining ring (2) into groove in

sprocket shaft bearing bore.

Installing Cylinder Base Studs

See

Figure 3-90

. If cylinder studs were removed, install them

as follows.

Pack clean towels into crankcase opening.

Place a steel ball into a head screw (1).

The cylinder studs (2) have a shoulder (3) at the lower
end. Place the end of the stud without the shoulder into
the head screw.

Install the stud in the crankcase with the shoulder end
down. Use an air gun (4) to drive the stud until the shoulder
reaches the crankcase.

Remove air gun. Use a torque wrench to tighten stud to
120-240 in-lbs (13.6-27.1 Nm).

sm01510

Head screw with ball inside

Cylinder stud

Shoulder on cylinder stud

Air gun

Figure 3-90. Cylinder Studs

CAM GEARS AND GEARCASE COVER: XL
MODELS

TOOL NAME

PART NUMBER

CRANKSHAFT LOCKING TOOL

HD-43984

See

Figure 3-91

. Make sure shaft key (18) is installed on

flywheel pinion shaft. Install oil pump drive gear (12) and
pinion gear (5) on pinion shaft.

NOTE

Timing mark on pinion gear tooth is aligned with keyway in I.D.
of pinion gear, as shown in

Figure 3-92

. The timing mark will

allow you to easily position pinion gear over shaft key and
against oil pump drive gear on pinion shaft.

See

Figure 3-91

. Clean threads on pinion shaft and nut

(11). Apply several drops of LOCTITE THREADLOCKER
262 (red) to threads of nut.

NOTE

Figure 3-91

. When using CRANKSHAFT LOCKING TOOL,

Do NOT use impact wrench to drive nut (11) onto pinion shaft.

2009 Sportster Service: Engine 3-83

sm01593

11.

Nut

Rear exhaust cam gear

12.

Rear intake cam gear

Oil pump drive gear

13.

Cam gear bushing (4)

Front intake cam gear

14.

Front exhaust cam gear

Rear exhaust cam gear bushing

15.

Rear intake cam gear bushing

Pinion gear

16.

Screw (11)

Pinion shaft bushing

17.

Gearcase cover

Front intake cam gear bushing

18.

Front exhaust cam gear bushing

T-key

19.

Cover plate

Gearcase cover gasket

10.

20.

Right crankcase

Screw (2)

Figure 3-91. Gearcase and Valve Train Components: XL Models

3-84 2009 Sportster Service: Engine

sm03418

Keyway

Timing mark at centerline of keyway

Figure 3-92. Pinion Gear Timing Mark and Keyway

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Pinion Gear

Shaft key

Oil pump drive gear

Pinion shaft

Figure 3-93. Oil Pump Drive Gear and Pinion Gear Installed

on Pinion Shaft

Figure 3-94

. Install CRANKSHAFT LOCKING

TOOL (Part No. HD-43984) over pinion shaft. Install nut
on pinion shaft. Tighten nut to 19-21 ft-lbs (26-29 Nm).
Then tighten nut an additional 15-19 degrees of rotation.
Remove CRANKSHAFT LOCKING TOOL (Part No. HD-
43984).

NOTE

Figure 3-95

. Because of the larger diameter additional

gear (which meshes with the pinion gear) on the outboard end
of the rear intake (2) cam gear, the rear exhaust (1) and front
intake (3) cam gears must both be installed before the rear
intake cam gear is installed.

Lubricate all cams and all cam bushings in right crankcase
with clean Harley-Davidson 20W-50 engine oil.

See

Figure 3-95

. Rotate crankshaft until timing mark on

pinion gear (5) points exactly at centerline of rear intake
cam bushing.

sm03420

Figure 3-94. Crankshaft Locking Tool (Part No. HD-43984)

Install rear exhaust cam (1). Rotate cam until timing mark
(a slot) points exactly at centerline of rear intake cam
bushing.

Install front intake cam (3). Rotate cam until slotted timing
mark points exactly at centerline of rear intake cam
bushing.

NOTE

See

Figure 3-95

. "V" marks on rear intake cam (2) are not used

for timing of Sportster model engines.

Install rear intake cam (2). As you install this cam, rotate
it so that the three timing marks (dots) line up exactly with
timing marks on the pinion gear, rear exhaust cam and
front intake cam.

Install front exhaust cam (4). As you install this cam, rotate
it so that its timing mark (a dot) lines up with timing mark
(dot) of front intake cam.

NOTE

Make sure all timing marks on cams just installed line up cor-
rectly, as shown in

Figure 3-95

. If necessary, remove a cam,

rotate it slightly, and re-install it. If timing marks are off even
one tooth, engine will not run correctly.

10. See

Figure 3-91

. Install a new dry gasket (9) on gearcase

cover (17).

2009 Sportster Service: Engine 3-85

sm03421

Rear exhaust cam gear (1W)

Rear intake cam gear (2W)

Front intake cam gear (3W)

Front exhaust cam gear (4W)

Pinion gear

Figure 3-95. Cam, Pinion Gear and Timing Mark Indexing (Cam #2 "V" marks are not used for timing)

11. Lubricate all cam bushings in gearcase cover with clean

Harley-Davidson 20W-50 engine oil.

12. Install gearcase cover over all gears and onto right

crankcase. Secure cover to crankcase with 11 socket head
screws. Tighten screws evenly to 80-110 in-lbs (9.0-12.4
Nm) according to the tightening sequence shown in

Figure 3-96

8997

Figure 3-96. Gearcase Cover Mounting Screw Torque

Sequence

13. Check cam gear end play through tappet bores in right

crankcase, for each cam gear as follows:

Turn engine over until lobe of cam gear being checked
is pointing toward its respective tappet guide hole.

Using a flat blade screwdriver, gently pry cam gear
toward gearcase cover.

Using a feeler gauge, measure gap between bushing
(in crankcase) and cam gear shaft thrust face
(shoulder). This is cam gear end play.

Compare your cam gear end play measurements with
the

3.2 SPECIFICATIONS

. Make repairs as required

if end gap is less than the minimum specified, or
greater than the maximum specified (Service Wear
Limits).

CAM GEARS AND GEARCASE COVER: XR
MODELS

TOOL NAME

PART NUMBER

CRANKSHAFT LOCKING TOOL

HD-43984

See

Figure 3-97

. Make sure shaft key (10) is installed on

flywheel pinion shaft. Install spacer (7) and pinion gear (6)
on pinion shaft.

3-86 2009 Sportster Service: Engine

NOTE

Timing mark on pinion gear tooth is aligned with keyway in I.D.
of pinion gear, as shown in

Figure 3-98

. The timing mark will

allow you to easily position pinion gear over shaft key and
against oil pump drive gear on pinion shaft.

See

Figure 3-97

. Clean threads on pinion shaft and nut

(5). Apply several drops of LOCTITE THREADLOCKER
262 (red) to threads of nut.

sm05005

Pinion gear

Right crankcase half

Rear exhaust cam gear

Spacer

Front intake cam gear

Cam gear bushing (4)

Rear intake cam gear

Front exhaust cam gear

10.

T-key

Nut

Figure 3-97. Gearcase and Valve Train Components: XR Models

sm03418

Keyway

Timing mark at centerline of keyway

Figure 3-98. Pinion Gear Timing Mark and Keyway

NOTE

Figure 3-99

. When using CRANKSHAFT LOCKING TOOL,

Do NOT use impact wrench to drive nut onto pinion shaft.

Figure 3-99

. Install CRANKSHAFT LOCKING

NOTE

Figure 3-100

. Because of the larger diameter gear on the

outboard end of the rear intake cam gear (2), the rear exhaust
(1) and front intake (3) cam gears must be installed before the
rear intake cam gear is installed.

Lubricate all cams and all cam bores in right crankcase
with clean Harley-Davidson 20W-50 engine oil.

See

Figure 3-100

. Rotate crankshaft until timing mark on

pinion gear (5) points exactly at centerline of rear intake
cam bore.