Harley Davidson Sportster Models 2009. Service Repair Manual — page 63

2009 Sportster Service: Fuel System 4-61

4.19

FUEL PRESSURE TEST

GENERAL

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)

The fuel pump delivers fuel to the fuel hose, a cavity in the
induction module that supplies the fuel injectors, and to the
pressure regulator. Excess fuel pressure is bypassed to the
fuel tank through the pressure regulator.

See

Figure 4-83

. The fuel pump fuse is located in a fuse panel

behind the left side cover. The fuel pump can be turned on with
DIGITAL TECHNICIAN II (Part No. HD-48650) or by applying
battery voltage to the fuel pump fuse.

Improper fuel system pressure may contribute to one of the
following conditions:

•

Cranks, but won't run.

•

Cuts out (may feel like ignition problem).

•

Hesitation, loss of power or poor fuel economy.

NOTE

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for further
information on the function and testing of the fuel system.

sm01653

Figure 4-83. Fuel Pump Fuse

TESTING

TOOL NAME

PART NUMBER

FUEL PRESSURE GAUGE

HD-41182

FUEL PRESSURE GAUGE ADAPTER

HD-44061

NOTE

Be sure to avoid kinking the fuel hose when installing or
removing fuel pressure gauge and adapter.

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.6 FUEL TANK: XL MODELS

. Attach FUEL PRESSURE GAUGE

ADAPTER (Part No. HD-44061) (1) as follows:

Figure 4-85

. Pull up on sleeve of fuel tank quick-

connect fitting (2) and insert neck of FUEL PRES-
SURE GAUGE ADAPTER (3) into quick-connect fit-
ting.

While pushing up on bottom of adapter, pull down on
sleeve until it "clicks" into the locked position. Tug on
adapter to be sure that it is locked in place and will
not come free.

In the same manner, connect vehicle's fuel supply
hose fitting (1) to quick-connect fitting (4) on FUEL
PRESSURE GAUGE ADAPTER.

To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)

Verify that the fuel valve (item 6,

Figure 4-85

.) and air

bleed petcock on the FUEL PRESSURE GAUGE (Part
No. HD-41182) are closed.

Figure 4-84

. Remove protective cap from free end of

fuel pressure gauge adapter. Connect fuel pressure gauge
to Schroeder valve.

Start and idle engine to pressurize the fuel system. Open
the fuel valve to allow the flow of fuel down the hose of
the pressure gauge.

Position the clear air bleed tube in a suitable container
and open and close the air bleed petcock to purge the
gauge and hose of air. Repeat this step several times until
only solid fuel (without bubbles) flows from the air bleed
tube. Close the petcock.

Open and close throttle to change engine speed. Note the
reading of the pressure gauge. Fuel pressure should
remain steady at 55-62 psi (380-425 kPa).

NOTE

If fuel pressure gauge reading is not within specifications, see
ELECTRICAL DIAGNOSTIC MANUAL for further diagnosis.

4-62 2009 Sportster Service: Fuel System

Turn the engine OFF. Position the air bleed tube in a
suitable container. Open the air bleed petcock to relieve
the fuel system pressure and purge the pressure gauge
of gasoline.

Gasoline can drain from the adapter when gauge is
removed. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
Wipe up spilled fuel immediately and dispose of rags in a
suitable manner. (00254a)

Remove fuel pressure gauge from the adapter. Install
protective cap over Schroeder valve.

Gasoline can drain from the fuel line and adapter when
removed. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
Wipe up spilled fuel immediately and dispose of rags in a
suitable manner. (00255a)

10. Pull up on knurled sleeve of FUEL PRESSURE GAUGE

ADAPTER quick-connect fitting and remove vehicle's fuel
supply hose from adapter. Release adapter from fuel tank
in the same manner.

To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)

11. Push up on release sleeve of fuel pump quick-connect

fitting and push fuel hose fitting into quick-connect fitting.
Pull down on release sleeve to lock quick-connect fitting.
Tug on fuel hose fitting to make sure it is securely locked
in place.

sm01654

Adapter

Quick-connect fitting

Protective cap

Fuel tank fitting (neck)

Figure 4-84. Fuel Pressure Gauge Adapter (Part No.

HD-44061)

sm01656

Fuel supply hose fitting

Fuel tank quick-connect fitting

Fuel pressure guage adapter

Adapter quick-connect fitting

Pressure adapter/Schroeder valve fitting

Fuel valve (closed position)

Figure 4-85. Assembling Adapter, Gauge and Fuel Supply

Hose to Fuel Tank: All Models (XL 1200C Shown)

sm01657

Figure 4-86. Fuel Pressure Gauge Installed: All Models (XL

1200C Shown)

2009 Sportster Service: Fuel System 4-63

4.20

INTAKE LEAK TEST

GENERAL

Do not allow open flame or sparks near propane. Propane
is extremely flammable, which could cause death or ser-
ious injury. (00521b)

Read and follow warnings and directions on propane
bottle. Failure to follow warnings and directions can result
in death or serious injury. (00471b)

NOTES

•

To prevent false readings, keep air cleaner cover installed
when performing test.

•

Do not direct propane into air cleaner; false readings will
result.

•

Be careful when testing vehicle with Screamin' Eagle air
cleaner assembly. This type of air cleaner has an open
backing plate. Even with air cleaner cover on, directing
nozzle too close to backing plate can give false readings.

LEAK TESTER

TOOL NAME

PART NUMBER

PROPANE ENRICHMENT KIT

HD-41417

Parts List

•

Standard 14 oz. propane cylinder.

•

PROPANE ENRICHMENT KIT (Part No. HD-41417).

Tester Assembly

See

Figure 4-87

. Make sure valve knob (6) is closed (fully

clockwise).

Screw valve assembly (5) onto propane bottle (1).

Tester Adjustment

Figure 4-87

. Press and hold trigger button (8).

Slowly open valve knob (6) until pellet in flow gauge (7)
rises to between 5 and 10 SCFH on gauge.

Release trigger button.

sm02629

Propane bottle

Nozzle

Copper tube

Hose

Valve assembly

Valve knob

Flow gauge

Trigger button

Hanger

Figure 4-87. Leak Tester

PROCEDURE

Start engine.

Warm up engine to operating temperature.

NOTE

Do not direct propane stream toward air cleaner. If propane
enters air cleaner, a false reading will be obtained.

See

Figure 4-88

. Aim nozzle (3) toward possible sources

of leak such as intake manifold mating surfaces.

Press and release trigger button (2) to dispense propane.
Tone of engine will change when propane enters source
of leak. Repeat as necessary to detect leak.

4-64 2009 Sportster Service: Fuel System

When test is finished, close valve knob (turn knob fully
clockwise).

sm01661

Propane bottle

Trigger button

Nozzle

Figure 4-88. Checking for Leaks: All Models (XL 1200C

Shown)

2009 Sportster Service: Fuel System 4-65

4.21

EVAPORATIVE EMISSIONS CONTROL (CA
MODELS)

GENERAL

Harley-Davidson motorcycles sold in the state of California are
equipped with an evaporative (EVAP) emissions control system.
The EVAP system prevents fuel hydrocarbon vapors from
escaping into the atmosphere and is designed to meet the
California Air Resource Board (CARB) regulations in effect at
the time of manufacture.

See

Figure 4-89

. The EVAP functions in the following manner:

•

Hydrocarbon vapors in the fuel tank (2, 10) are directed
through the vapor valve (4) or vent fitting (9) and stored
in the charcoal canister (3). If the vehicle is tipped at an
abnormal angle, the vapor valve closes to prevent liquid
gasoline from leaking out of the fuel tank into the charcoal
canister through the vapor valve hoses (5, 6).

•

When the engine is not running, the gravity operated trap
door in the air cleaner's snorkel is closed to seal the inlet
port of the air cleaner backplate. This prevents hydro-
carbon vapors emanating from the induction module throat
from escaping into the atmosphere.

•

When the engine is running, the vacuum created in the
inlet pulls the gravity-operated trap door open allowing air
to enter. Intake venturi negative pressure (vacuum) slowly
draws off the hydrocarbon vapors from the charcoal can-
ister through the canister-to-induction module purge hose.
These vapors pass through the intake and are burned as
part of normal combustion in the engine.

Keep evaporative emissions vent lines away from exhaust
and engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00266a)

NOTE

The EVAP system has been designed to operate with a min-
imum of maintenance. Check that all hoses are properly con-
nected, are not pinched, kinked, cracked or torn, and are routed
properly. Improper connections could leak charcoal from can-
ister.

sm03399a

Induction module

Fuel tank (XL models only)

Charcoal canister

External vapor valve (XL models only)

Fuel tank-to-vapor valve hose

Vapor valve-to-canister hose

Purge hose

Fuel supply hose

Vent fitting (XR models only)

10. Fuel tank (XR models only)

Figure 4-89. California Evaporative Emissions Control

System (typical)

4-66 2009 Sportster Service: Fuel System

CHARCOAL CANISTER

The charcoal canister is mounted to a bracket attached to the
rear brake master cylinder bracket, near the bottom of the
frame in front of the rear fork pivot point.

Removal

2.15 REAR BRAKE MASTER CYLINDER RESER-
VOIR

. Remove two screws (1) and canister

guard (2).

Mark the two hoses (9, 10) connected to charcoal canister
(6). Disconnect hoses from canister.

Depress locking tabs at left end of canister clip (5). Slide
canister towards left side of vehicle until it disengages
from canister clip.

Remove two screws (7) and washers (8) to detach canister
clip from canister mounting bracket (3).

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.

XL Models: If canister mounting bracket requires
repair/replacement, proceed as follows:

Drain rear master cylinder reservoir and detach
reservoir hose from rear master cylinder. See

Remove two screws (4) to detach canister mounting
bracket from rear master cylinder mounting bracket.

XR Models: See

Figure 4-91

. If canister mounting bracket

requires repair/replacement, remove two screws (2) to
detach canister mounting bracket from frame.

NOTE

It is not necessary to remove brake line clamp screw (1).

sm01647

Screw (2)

Canister guard

Canister mounting bracket

Screw (2)

Canister clip

Charcoal canister

Screw (2)

Washer (2)

Purge hose from induction module

10. Vent hose from vapor valve

Figure 4-90. Charcoal Canister Mounting (Typical)

sm05430

Screw

Canister mounting bracket screws (2)

Canister mounting bracket

Fuel tank-to-canister hose

Canister-to-induction module hose

Figure 4-91. Charcoal Canister Mount: XR Models

2009 Sportster Service: Fuel System 4-67

Installation

NOTE

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

XL Models: See

2.15 REAR BRAKE MASTER CYLINDER RESER-
VOIR

. If canister mounting bracket

(3) was removed, proceed as follows:

Attach bracket (3) and rear brake line bracket (not
visible) to rear master cylinder mounting bracket and
frame with two screws (4). Tighten to 17-22 ft-lbs
(23.1-29.9 Nm).

Attach rear master cylinder reservoir feed hose to
rear master cylinder feed hose port fitting.

With motorcycle upright, fill reservoir with Harley-
Davidson D.O.T. 4 BRAKE FLUID until the fluid level
reaches the UPPER mark on the reservoir. See

Bleed rear brake system. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

XR Models: See

Figure 4-91

. If canister mounting bracket

(3) was removed, proceed as follows:

Apply Loctite Threadlocker 243 (blue) to the threads
of the mounting screws (2).

Install bracket and tighten screws (2) to 17-22 ft-lbs
(23.1-29.9 Nm).

See

. Attach canister clip (5) to canister

mounting bracket with two screws (7) and two washers
(8). Tighten to 36-60 in-lbs (4.1-6.8 Nm).

Starting at left side of canister clip, slide charcoal canister
(6) to the right until tabs on canister clip lock canister in
place. Bend tabs outward somewhat if canister is not held
securely.

Figure 4-92

. Connect two hoses (1, 2), marked during

disassembly, to their proper fittings on canister.

See

4.7 FUEL TANK: XR MODELS

. Install canister guard (2) using two

screws (1). Tighten to 35-45 in-lbs (4.0-5.1 Nm).

sm01648

Purge hose from induction module

Vent hose from fuel tank and vapor valve

Clean air port (no hose connection)

Figure 4-92. Charcoal Canister Connections

VAPOR VALVE: XL MODELS

Removal

NOTES

•

On XL Models, the vapor valve is located beneath the seat
in front of the battery, in a clip molded into frame-mounted
H-bracket.

•

On XR Models, the vapor valve in incorporated in the fuel
tank filler housing. See

for

service procedures.

Open left side cover. See

2.20 LEFT SIDE COVER

See

Figure 4-93

. Carefully remove vapor valve (2) from

clip (4) molded into H-bracket (6).

Mark two hoses (1, 3) connected to upper and lower fittings
of vapor valve. Remove hoses from fittings.

NOTE

On non-California models, charcoal canister is absent and
bottom hose of vapor valve is vented to the atmosphere.

Installation

Keep vent and vapor valve lines away from exhaust and
engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00263a)

4-68 2009 Sportster Service: Fuel System

NOTE

Mount the vapor valve in an upright position with the longer
fitting positioned at the top or excessive fuel vapor pressure
may build up within the fuel tank. Mounting the vapor valve
upside down will result in fuel flow problems.

, and then see Canister Hose Routings.

Figure 4-93

. Hold vapor valve (2) in an upright position

with the long necked end pointing up. Insert top fitting of
vapor valve into fuel tank-to-vapor valve hose (1). Install
bottom vapor valve fitting into vapor valve-to-canister hose
(3).

Carefully push body of vapor valve into clip (4) molded
into H-bracket (6).

NOTE

Do NOT force vapor valve into clip. Forcing valve in to clip
could cause clip to break, necessitating replacement of entire
wiring harness guide.

Close left side cover.

sm01649

Fuel tank-to-vapor valve hose

Vapor valve

Vapor-valve-to-canister hose

Vapor valve clip

Canister-to-induction module purge hose

H-bracket

To fuel tank

To charcoal canister

Figure 4-93. Vapor Valve and Hose Routing: XL California

Models

HOSE ROUTING

See

Figure 4-89

Induction Module

See

Figure 4-94

. Route the evaporative emissions control hose

at the induction module as shown. For XL models: to access

2009 Sportster Service: Fuel System 4-69

the hose, remove the fuel tank and air cleaner/backplate
assembly as necessary.

sm01651

Induction module

Purge hose (to canister) fitting

Figure 4-94. Emissions Hose Routing at Induction Module

Canister Hose Routings: XL Models

Figure 4-93

. Connect vapor valve-to-canister hose

(3) and canister-to-induction module purge hose (5) to
labeled fittings on left side of charcoal canister.

Route both hoses up behind rear brake reservoir hose,
between rear fork pivot point and rear end of crankcase.

Connect vapor valve-to-canister hose to bottom of vapor
valve (2).

Connect fuel tank-to-vapor valve hose (1) at top of vapor
valve.

See

Figure 4-95

. Route fuel tank-to-vapor valve hose (2)

forward along left side of frame backbone and connect to
fitting on bottom of fuel tank (1).

Route canister-to-induction module purge hose up right
side of frame rear downtube. Continue routing hose for-
ward along right side of frame backbone tube and down,
connecting hose to induction module fitting.

Secure hose to boss on rear end of right wire harness
caddy with a barbed cable strap. Press barbed prong of
cable strap into hole in caddy boss. Ensure that hose is
positioned up against engine sub-harness. Hose should
be routed as far from rear rocker cover as possible.

sm01652

Fuel tank

Fuel tank-to-vapor valve hose

Figure 4-95. Fuel Tank-to-Vapor Valve Hose Routing

Canister Hose Routings: XR Models

Figure 4-96

. Route both hoses up past canister mount

and between rear fork pivot point and rear end of crank-
case as shown.

Figure 4-97

. Route fuel vapor hose (4) up along left

side of frame rear downtube and outside the left electrical
caddy. Connect to vapor tube (2).

Connect vapor tube (2) to fitting (1) on fuel tank filler
housing and place in channel on top of fuel tank.

Secure to electrical caddy with barbed clamp (3).

Figure 4-98

. Route canister-to-induction module purge

hose (1) up right side of frame rear downtube. Continue
routing hose forward along right side of frame backbone
tube and down, connecting hose to induction module fitting
(3).

Secure hose to channels on rear end of right wire harness
caddy (4). Ensure that hose is positioned up against
engine sub-harness. Secure hose and harness with clamp
(2).

Connect hoses to labeled fittings on left side of charcoal
canister.

4-70 2009 Sportster Service: Fuel System

sm05430

Screw

Canister mounting bracket screws (2)

Canister mounting bracket

Fuel tank-to-canister hose

Canister-to-induction module hose

Figure 4-96. Charcoal Canister Mount: XR Models

sm05436

Vapor fitting

Vapor tube

Clamp

Vapor hose

Figure 4-97. Vapor Hose Routing

sm05437

Purge hose

Clamp

Induction module fitting

Right wire harness caddy

Figure 4-98. Purge Hose Routing

2009 Sportster Service: Fuel System 4-71

TABLE OF CONTENTS

SUBJECT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE NO.

DRIVE/TRANSMISSION

5.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

5.7 DRIVE BELT, Installation

129-142 Nm

95-105 ft-lbs

Axle nut, rear

5.7 DRIVE BELT, Installation

129-142 Nm

95-105 ft-lbs

Axle nut, rear

5.7 DRIVE BELT, Installation

13.6-20.3 Nm

120-180 in-lbs

Belt guard screw, front

5.3 PRIMARY CHAIN ADJUSTER, Installation

4.1-6.8 Nm

36-60 in-lbs

Clutch cable end fitting

5.3 PRIMARY CHAIN ADJUSTER, Installation

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

5.4 CLUTCH RELEASE MECHANISM, Assembly
and Installation

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

5.15 TRANSMISSION INSTALLATION, Shifter
Shaft Installation

44.8-50.2 Nm

33-37 ft-lbs

Countershaft retaining screw

5.15 TRANSMISSION INSTALLATION, Assembling
Crankcases

20.3-25.8 Nm

15-19 ft-lbs

Crankcase fastener

5.6 PRIMARY DRIVE AND CLUTCH: XR
MODELS, Installation

210.0-224.0 Nm

155-165 ft-lbs

Engine sprocket bolt: XR Models

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Installation

326-353 Nm

240-260 ft-lbs

Engine sprocket nut

5.7 DRIVE BELT, Installation

9.0-13.6 Nm

80-120 in-lbs

Exhaust pipe clamp bracket final screws

5.7 DRIVE BELT, Installation

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket initial screw

5.16 TRANSMISSION SPROCKET, Installation

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket screw

5.7 DRIVE BELT, Installation

9.0-13.6 Nm

80-120 in-lbs

Forward and lower sprocket cover
screws: XR models

5.15 TRANSMISSION INSTALLATION, Installation

10.2-12.4 Nm

90-110 in-lbs

Gear detent assembly screw

5.3 PRIMARY CHAIN ADJUSTER, Installation

21.7-27.1 Nm

16-20 ft-lbs

Gear shift lever pinch screw

5.7 DRIVE BELT, Idler Pulley: XR Models Only

45-47 Nm

33-35 ft-lbs

Idler pulley bracket flanged nut: XR
models

5.7 DRIVE BELT, Idler Pulley: XR Models Only

95-109 Nm

70-80 ft-lbs

Idler pulley fastener: XR models

5.7 DRIVE BELT, Installation

61-68 Nm

45-50 ft-lbs

Lower shock absorber screw

5.7 DRIVE BELT, Installation

61-68 Nm

45-50 ft-lbs

Lower shock absorber screw

5.16 TRANSMISSION SPROCKET, Installation

40.7-44.8 Nm

30-33 ft-lbs

Muffler interconnect bracket mounting
screw

5.15 TRANSMISSION INSTALLATION, Assembling
Crankcases

13.6-20.3 Nm

120-180 in-lbs

Neutral indicator switch

5.3 PRIMARY CHAIN ADJUSTER, Installation

27.1-33.9 Nm

20-25 ft-lbs

Primary chain adjuster lock nut

5.3 PRIMARY CHAIN ADJUSTER, Installation

11.3-13.5 Nm

100-120 in-lbs

Primary cover screw

5.3 PRIMARY CHAIN ADJUSTER, Installation

19.0-40.7 Nm

14-30 ft-lbs

Primary drain plug

5.7 DRIVE BELT, Installation

40.7-44.7 Nm

30-33 ft-lbs

Rear sprocket cover screw: XR models

5.4 CLUTCH RELEASE MECHANISM, Assembly
and Installation

61-68 Nm

45-50 ft-lbs

Rider footrest support bracket mounting
screw

5.16 TRANSMISSION SPROCKET, Installation

61-68 Nm

45-50 ft-lbs

Rider footrest support mounting bracket

5.7 DRIVE BELT, Installation

4.1-6.8 Nm

36-60 in-lbs

Secondary drive belt deflector screws

5.7 DRIVE BELT, Idler Pulley: XR Models Only

40.7-44.8 Nm

30-33 ft-lbs

Sprocket cover fastener, large: XR
models

2009 Sportster Service: Drive/Transmission 5-1

NOTES

TORQUE VALUE

FASTENER

5.16 TRANSMISSION SPROCKET, Installation

40.7-44.8 Nm

30-33 ft-lbs

Sprocket cover fastener, large: XR
models

5.7 DRIVE BELT, Idler Pulley: XR Models Only

9.0-13.6 Nm

80-120 in-lbs

Sprocket cover fastener, small: XR
models

5.16 TRANSMISSION SPROCKET, Installation

9.0-13.6 Nm

80-120 in-lbs

Sprocket cover fastener, small: XR
models

5.16 TRANSMISSION SPROCKET, Installation

9.0-13.6 Nm

80-120 in-lbs

Sprocket cover screw

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Installation

95.0-108.6 Nm

70-80 ft-lbs

Transmission mainshaft nut

5.6 PRIMARY DRIVE AND CLUTCH: XR
MODELS, Installation

95.0-108.6 Nm

70-80 ft-lbs

Transmission mainshaft nut

5.16 TRANSMISSION SPROCKET, Installation

10.2-12.4 Nm

90-110 in-lbs

Transmission sprocket lockplate

5.16 TRANSMISSION SPROCKET, Installation/See
TRANSMISSION SPROCKET section for special
procedure.

68 Nm

50 ft-lbs

Transmission sprocket nut

5-2 2009 Sportster Service: Drive/Transmission

5.2

SPECIFICATIONS: DRIVE

2009 SPORTSTER SPECIFICATIONS

Table 5-1. Sprocket Teeth: 2009 Sportster Models

NUMBER OF TEETH

ITEM

DRIVE

XR 1200

XL 1200 MODELS

XL 883 MODELS

JAPAN

MODELS

WORLD

MODELS

WORLD

MODELS

U.S.

MODELS

WORLD

MODELS

U.S.

MODELS

Engine

Primary

Clutch

Transmission

Final

Rear wheel

Table 5-2. Overall Gear Ratios: 2009 Sportster Models

XR 1200 MODEL

XL 1200 MODELS

XL 883 MODELS

GEAR

JAPAN

MODELS

WORLD

MODELS

WORLD

MODELS

U.S.

MODELS

ALL

MODELS

9.647

10.782

9.004

9.315

10.782

1st

6.891

7.702

6.432

6.653

7.702

2nd

5.125

5.728

4.783

4.948

5.728

3rd

4.248

4.748

3.965

4.102

4.748

4th

3.643

4.071

3.400

3.517

4.071

5th

NOTE

Service wear limits are given as a guideline for measuring
components that are not new. For measurement specifications

not given under SERVICE WEAR LIMITS, see NEW COMPON-
ENTS.

Table 5-3. Wet Clutch Multiple Disc Specifications

SERVICE WEAR LIMITS

NEW COMPONENTS

ITEM

CLUTCH PLATE THICKNESS

N/A

2.200 ± 0.079

0.8666 ± 0.0031

Friction plate (fiber)

N/A

1.598 ± 0.051

0.0629 ± 0.0020

Steel plate

16.787 (minimum)

0.6610 (minimum)

N/A

Clutch pack

MAXIMUM ALLOWABLE WARPAGE

0.150

0.0059

N/A

Friction plate (fiber)

0.150

0.0059

N/A

Steel plate

2.40 RIDER FOOT CONTROLS: XL MODELS

2009 Sportster Service: Drive/Transmission 5-3

5.3

PRIMARY CHAIN ADJUSTER

GENERAL

The primary chain adjuster mechanism maintains proper ten-
sion on the primary chain.

An opening between the primary drive and transmission com-
partments allows the same lubricant supply to lubricate moving
parts in both areas. Since the primary chain runs in lubricant,
little service will be required other than checking lubricant level
and chain tension. If, through hard usage, the primary chain
does become worn, it must be replaced. Remove and install
the chain following the procedure under

5.5 PRIMARY DRIVE

AND CLUTCH: XL MODELS

REMOVAL

Primary Cover

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)

Disconnect negative (-) battery cable from stud on engine
crankcase behind starter motor assembly. See

1.17 BATTERY MAINTENANCE

Open left side cover. See

2.20 LEFT SIDE COVER

Remove positive (+) battery cable from battery positive
(+) terminal. See

1.17 BATTERY MAINTENANCE

Close left side cover.

Remove left side rider footrest and mounting bracket
assembly.

Models equipped with mid-mount foot controls:
see

EQUIPPED WITH MID-MOUNT CONTROLS

2.42 RIDER FOOT CONTROLS: XR MODELS

for

removal procedure.

Models equipped with forward foot controls: see

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS

for

removal procedure.

Figure 5-1

. Place a drain pan under the engine.

Remove drain plug (4) and drain lubricant from primary
drive housing.

Loosen lock nut (6). Turn chain adjuster screw (5) coun-
terclockwise to relax primary chain tension.

Remove gear shifter lever and rubber washer from trans-
mission shifter shaft.

Figure 5-2

. Slide rubber boot (1) on clutch cable

adjuster (2) upward to expose adjuster mechanism.
Loosen jam nut (3) from adjuster. Turn adjuster to shorten
cable housing until there is a large amount of freeplay at
clutch hand lever. See

1.13 CLUTCH, Adjustment

10. See

Figure 5-3

. Remove six screws (1) and clutch

inspection cover (2). Remove quad ring (7) from groove
in primary cover (8). Discard quad ring.

11. Slide hex lockplate and attached spring (3) from flats of

adjusting screw (9).

12. Turn adjusting screw clockwise to release ramp assembly

(5) and coupling mechanism (6). As the adjusting screw
is turned, ramp assembly moves forward. Remove nut (4)
from end of adjusting screw.

13. Remove hook of ramp from cable coupling. Remove clutch

cable end from slot in coupling. Remove coupling and
ramp assembly.

14. Turn cable end fitting (14) counterclockwise to remove

clutch cable lower section from primary cover. Remove
and discard o-ring (12) from cable end fitting.

15. Remove sixteen screws with captive washers (11) securing

primary cover to engine crankcase. Remove cover and
gasket (10). Discard gasket.

16. See

Figure 5-4

. Remove and discard shifter shaft oil seal

(4).

17. Clean all metal parts in a non-volatile cleaning solution or

solvent.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

18. Blow parts dry with low pressure compressed air.

sm03278

Primary chain inspection cover

Primary cover

Clutch inspection cover

Drain plug

Primary chain adjuster screw

Lock nut

Figure 5-1. Primary Cover: All Models (XL Model Shown)