Harley Davidson Sportster Models 2009. Service Repair Manual — page 25
2.
Inspect fork stem and lower bracket (1). Replace if dam-
aged.
3.
Carefully inspect bearing races and assemblies for pitting,
scoring, wear and other damage. Check for roughness of
bearings by turning them in their races. Replace bearings
and bearing cups if bearings do not turn freely and
smoothly. Replace damaged bearings as a set.
Replace both bearing assemblies even if one assembly
appeares to be good. Mismatched bearings can lead to
excessive wear and premature replacement. (00532b)
4.
Replace bearings and bearing cups as follows:
a.
The lower bearing cone is a slip fit on the fork stem.
Remove lower bearing cone by sliding it up and off
fork stem. If necessary, gently pry bearing cone off
fork stem with a pair of flat blade screw drivers.
Remove lower seal (2).
b.
Drive bearing cups from steering head using
STEERING HEAD BEARING RACE REMOVAL
TOOL (Part No. HD-39301-A) and UNIVERSAL
DRIVER HANDLE (Part No. HD-33416). If bearing
cups are removed, the bearings cannot be reused.
They must be replaced.
ASSEMBLY AND INSTALLATION
TOOL NAME
PART NUMBER
STEERING HEAD BEARING RACE
INSTALLATION TOOL
HD-39302
1.
. If bearing cups (4) were removed, obtain
new bearings and bearing cups. Install new bearing cups
into frame steering head using STEERING HEAD
BEARING RACE INSTALLATION TOOL (Part No. HD-
39302).
Properly seat bearing cups in steering head bore. Improper
seating can loosen fork stem bearings adversely affecting
stability and handling, which could result in death or ser-
ious injury. (00302a)
2.
Liberally coat the bearing cones (3) with HARLEY-DAV-
IDSON SPECIAL PURPOSE GREASE. Work the grease
thoroughly into the bearing rollers.
3.
Place lower bearing seal (2) over fork stem. Install lower
bearing cone (3) onto fork stem and bracket (1).
4.
Insert fork stem and bracket (1) through the steering head.
Install bearing cone (3) and seal (5) onto the stem.
5.
Install the upper bracket (6) including the handlebar
assembly and loosely install fork stem bolt (9) with washer
(8).
6.
Install fork slider and tube assemblies. See
or
Leave both lower fork bracket pinch screws (12) loose.
7.
Tighten fork stem bolt (9) to 23-27 ft-lbs (31.2-36.6 Nm).
Loosen fork stem bolt, then retighten to 72-96 in-lbs (8.1-
10.9 Nm).
8.
Tighten lower fork bracket pinch screws to 30-35 ft-lbs
(40.7-47.5 Nm)
9.
Tighten fork stem pinch screw (7) to 30-35 ft-lbs (40.7-
47.5 Nm).
2009 Sportster Service: Chassis 2-127
2.24
BELT GUARD AND DEBRIS DEFLECTOR
BELT GUARD: XL MODELS
Removal
1.
. Remove right side lower shock absorber
mount lock nut (1). Pull shock absorber mounting screw
(2) out slightly until it clears mounting hole in belt guard
(4).
2.
Remove screw (5), washer (6) and nut (7) securing front
of belt guard to rear fork (10).
3.
Remove belt guard from vehicle.
Installation
1.
See
. Slide belt guard (4) into place on
vehicle. Tab on front of belt guard mounts outboard of
mounting bracket on rear fork.
2.
Secure front of belt guard to rear fork (10) with screw (5),
washer (6) and nut (7). Tighten to 120-180 in-lbs (13.6-
20.4 Nm).
3.
Push lower shock absorber mounting screw (2) through
rear belt guard mounting hole. Thread lock nut (1) on
screw. Tighten to 45-50 ft-lbs (61-68 Nm).
DEBRIS DEFLECTOR: XL MODELS
Removal
1.
See
. Loosen, but do not remove, three
screws with captive washers (9) securing debris deflector
(8) to underside of rear fork (10).
2.
Slide debris deflector forward until keyway slots in deflector
clear screw heads. Remove debris deflector.
Installation
1.
See
. Position debris deflector (8) in place on
underside of rear fork (10).
2.
Fit large end of keyway slots in deflector over screw heads
and captive washers (9). Slide deflector rearward to lock
screws in slots. Tighten screws to 36-60 in-lbs (4.1-6.8
Nm).
3
2
8
9
10
5
6
7
1
4
sm02201
1.
Lock nut
2.
Screw
3.
Washer
4.
Belt guard
5.
Screw
6.
Washer
7.
Nut
8.
Debris deflector
9.
Screw w/captive washer (3)
10. Rear fork
Figure 2-202. Belt Guard/Debris Deflector: XL Models
BELT GUARD: XR MODELS
Removal
NOTE
. Note that exhaust system has been removed
for clarity. It is not necessary to remove exhaust system to
remove and replace belt guard and/or debris deflector.
1.
. Remove two screws with captive
washers (2) securing belt guard to top of rear fork (5).
2.
Remove belt guard from vehicle.
Installation
1.
See
. Slide belt guard (1) into place on top
of rear fork (5).
2.
Secure belt guard using two screws with captive washers
(2). Tighten to 72-96 in-lbs (8.1-10.8 Nm).
2-128 2009 Sportster Service: Chassis
DEBRIS DEFLECTOR: XR MODELS
Removal
1.
See
. Remove three screws with captive
washers (4) securing debris deflector (3) to underside of
rear fork (5). Note that front screw is located inboard of
debris deflector.
2.
Remove debris deflector from vehicle.
Installation
1.
See
. Position debris deflector (3) in place on
underside of rear fork (5).
2.
Secure with three screws (4). Tighten screws to 72-96 in-
lbs (8.1-10.8 Nm).
1
2
3
5
4
sm04892
1.
Belt guard
2.
Screw with captive washer (2)
3.
Debris deflector
4.
Screw with captive washer (3) (front screw
inboard of debris deflector)
5.
Rear fork
Figure 2-203. Belt Guard/Debris Deflector: XR Models
(Exhaust System Removed for Clarity)
2009 Sportster Service: Chassis 2-129
2.25
REAR FORK
GENERAL
The rear fork used on the XR model differs in appearance from
the XL model rear fork. However, the removal, servicing and
installation procedures are functionally identical.
REMOVAL
NOTE
Mark all hardware as it is removed so that it may be returned
to its original location.
1.
Support motorcycle under frame with suitable lifting device
so that rear wheel is off the ground.
2.
XL models: remove rear exhaust pipe and muffler. See
4.15 EXHAUST SYSTEM: XL MODELS
3.
XR models: remove exhaust system. See
.
4.
Remove rear wheel. See
.
5.
Remove rear brake caliper assembly from rear fork. See
2.16 REAR BRAKE CALIPER: XL MODELS
. Remove screw(s)
securing brake line clamp(s) to rear fork.
6.
XR Models: Remove fasteners securing brake line to left
side of rear fork.
7.
Remove both shock absorber screws, washers and nuts
from rear fork. See
8.
Remove rear belt guard and debris deflector. See
2.24 BELT GUARD AND DEBRIS DEFLECTOR
9.
XL Models: Remove rear brake reservoir cover by
grasping cover and gently pulling straight out from reser-
voir. Remove reservoir mounting screw and pull reservoir
back out of the way. See
10. XL Models: Loosen, but do not remove, top mounting
screw from left passenger footrest bracket. Remove bottom
mounting screw. Move brake hoses and B-clamp forward
slightly to gain access to left rear fork/engine mount bolt.
11. XR Models: Remove left and right rider footrests. See
2.42 RIDER FOOT CONTROLS: XR MODELS
.
12. See
. Support rear fork (3). Remove rear
fork/engine mount bolts (1) and pull fork assembly from
frame.
5
4
3
6
1
2
sm01818
1.
Bolt (2)
2.
Bearing (2)
3.
Rear fork
4.
Pivot shaft
5.
Frame
6.
Retaining ring
Figure 2-204. Rear Fork Assembly: All Models (XL Shown)
DISASSEMBLY
TOOL NAME
PART NUMBER
BEARING REMOVER/INSTALLER
TOOL
HD-46281
NOTE
. Remove pivot bearings (2) only if replace-
ment is required.
1.
S e e
. U s i n g B E A R I N G
REMOVER/INSTALLER TOOL (Part No. HD-46281) (4,
5, 6), carefully press bearing assemblies from fork bearing
bosses (2):
a.
Place receiver cup (6) on press bed, with recessed
end of cup facing up.
b.
Place rear fork pivot bearing boss (2) over cup as
shown in the photo.
c.
Slide pilot (5) through bearing and into receiver cup.
d.
Insert handle (4) through other rear fork pivot bearing
boss and bearing, down into pilot.
e.
Engage press ram on end of handle and press
bearing out.
2.
Turn rear fork over and press out other pivot bearing in
the same manner.
2-130 2009 Sportster Service: Chassis
1
3
4
5
6
2
sm01465
1.
Rear fork
2.
Pivot bearing boss
3.
Press
4.
Handle
5.
Pilot
6.
Receiver cup
Figure 2-205. Removing Rear Fork Pivot Bearings: All
Models (XL Shown)
CLEANING AND INSPECTION
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)
1.
Clean all components in solvent and blow dry with low
pressure compressed air. Carefully inspect bearings for
wear and/or corrosion. Replace bearing assembly if dam-
aged.
2.
. Make sure pivot bearing retaining ring
(6) is not bent or damaged. If it is, replace it with a new
retaining ring. Make sure retaining ring is fully seated in
the groove in each bearing (2).
3.
Check that rear fork (3) is not bent, twisted or cracked.
Replace if damaged.
ASSEMBLY
TOOL NAME
PART NUMBER
BEARING REMOVER/INSTALLER
TOOL
HD-46281
1.
See
. If necessary, press new bearings (2)
into position in rear fork, using BEARING
REMOVER/INSTALLER TOOL (Part No. HD-46281):
a.
. Place receiver cup (7) on press
bed, with recessed end of cup facing up.
b.
Place rear fork pivot bearing boss (2) over cup as
shown in the photo.
c.
Place new pivot bearing (6) over pivot bearing boss,
with retaining ring side of bearing up.
d.
Slide pilot (5) through new pivot bearing, through pivot
bearing boss, and into receiver cup.
e.
Insert handle (4) down into pilot.
f.
Engage press ram on end of handle and press
bearing down until retaining ring bottoms out in rear
fork pivot bearing boss.
2.
Turn rear fork over and in the same manner, press in other
pivot bearing into rear fork pivot bearing boss.
INSTALLATION
1.
Slide rear fork assembly into position on motorcycle.
2.
. Holding rear fork assembly in position,
install rear fork/engine mount bolts (1). Tighten to 60-70
ft-lbs (81.4-95.0 Nm).
3.
XL models: Position rear brake hose B-clamp and left
passenger footrest bracket in place and install lower
mounting screw. Tighten both mounting screws to 45-50
ft-lbs (61-68 Nm).
4.
XL models: Install rear brake reservoir using screw with
captive washer. Tighten to 20-25 in-lbs (2.3-2.8 Nm).
Place reservoir cover over reservoir and gently press cover
into place. See
2.15 REAR BRAKE MASTER CYLINDER
.
5.
XR models: Install left and right rider footrests. See
2.42 RIDER FOOT CONTROLS: XR MODELS
.
6.
Install belt guard and debris deflector. See
.
7.
Install shock absorbers onto rear fork. See
8.
Install rear brake caliper assembly. See
or
9.
XR models: Secure rear brake line to left side of fork. See
.
10. Install rear wheel and adjust rear belt. See
11. XL models: install rear exhaust pipe and muffler. See
4.15 EXHAUST SYSTEM: XL MODELS
.
12. XR models: install exhaust system. See
2009 Sportster Service: Chassis 2-131
2
1
3
4
5
6
7
4
5
6
7
sm01466
1.
Rear fork
2.
Pivot bearing boss
3.
Press
4.
Handle
5.
Pilot
6.
Bearing
7.
Receiver cup
Figure 2-206. Installing Rear Fork Pivot Bearings: All
Models (XL Shown)
2-132 2009 Sportster Service: Chassis
2.26
SHOCK ABSORBERS
GENERAL
When removing shock absorbers, remove and install one shock
absorber first, then the other. This will eliminate the need to
raise the rear end of the motorcycle. If it is necessary to remove
both shock absorbers at once, place the motorcycle on a suit-
able lift with the rear wheel raised off the ground.
See
1.20 SHOCK ABSORBER ADJUSTMENT
for information
on preload adjustment and suspension settings.
NOTE
Except for rubber mounting damper bushings, shock absorbers
are non-repairable items. If the shock absorber is leaking or
damaged, it must be replaced as an assembly.
REMOVAL
1.
If necessary, raise rear end of motorcycle with stand or
suitable blocking underneath frame. If blocking is not
available, remove one shock absorber at a time. The
remaining shock absorber will hold the rear fork and frame
in place.
2.
See
. Remove screw (1), washer (7) and lock
nut (9) from bottom end of shock absorber (6) or (15).
3.
Remove screw (2), washer (3) and stud cover (4) (XL
models) from top end of shock absorber.
4.
Remove shock absorber.
5.
If shock absorber is to be replaced, take note of the posi-
tion of the preload setting and adjust the replacement
shock absorber to the same setting.
CLEANING AND INSPECTION
Clean and inspect all parts for wear and damage. Check rubber
components for wear, cracking and stiffness. Examine shock
assembly for signs of leakage. Replace both shock absorbers
as a set if either shock absorber assembly is excessively worn,
leaking or damaged.
INSTALLATION
1.
. Install shock absorber upper mounting
screw (2), washer (3), stud cover (4) (XL models) and
shock absorber (6) or (15).
2.
Position bottom end of shock absorber against outboard
side of rear fork mount. Insert screw (1) and washer (7)
through damper bushing (8) and rear fork mount flange.
Install lock nut (9) on end of bolt.
3.
Remove upper mounting screw (2). Apply 2-3 drops of
LOCTITE THREADLOCKER 243 (blue) to threads of upper
mounting screw.
4.
Install washer (3) onto upper mounting screw. Insert screw
through stud cover (4), upper shock absorber damper
bushing (5) and into frame boss. Tighten to 45-50 ft-lbs
(61-68 Nm).
5.
Tighten lower shock absorber mounting screw to 45-50
ft-lbs (61-68 Nm).
6.
If the shock absorber just installed is a replacement, adjust
the preload setting to the same as the original shock
absorber.
2009 Sportster Service: Chassis 2-133
7
8
10
11
12
13
9
6
5
4
3
2
14
15
1
sm01819
9.
1.
Nut
Screw
2.
10.
Screw
Spring adjuster: XL models
11.
3.
Lower spring guide: XL models
Washer
4.
12.
Stud cover: XL models
Upper spring seat: XL models
13.
5.
Shock absorber cover: XL models
Upper bushing: XL models
6.
14.
Shock absorber: XL models
Upper bushing: XR models
15.
7.
Shock absorber: XR models
Washer
8.
Lower bushing
Figure 2-207. Shock Absorber: All Models (Right Side Shown)
2-134 2009 Sportster Service: Chassis
2.27
STABILIZER LINKS
GENERAL
The stabilizer link system allows the engine to "float" on its
rubber engine mounts while maintaining engine-to-frame
alignment. The stabilizer links provide a fixed alignment, and
no adjustment is necessary or possible.
UPPER FRONT STABILIZER LINK
Removal
1.
Position motorcycle upright on suitable lift.
2.
See
. Remove screws (4) and stabilizer link
(2).
3.
Remove upper frame bracket:
a.
Models with front mounted horn: remove screws
(5), washers (8), horn bracket (9), and upper frame
bracket (3) from frame.
b.
Models with side mounted horn: remove screws
(5), washers (8) and upper frame bracket (3) from
frame.
4.
Remove screws (6), lock washers (7) and engine bracket
(1) from front cylinder head.
Installation
1.
See
. Install screws (6), lock washers (7) and
engine bracket (1) to front cylinder head. Tighten to 55-65
ft-lbs (74.6-88.2 Nm).
2.
Install upper frame bracket:
a.
Models with front mounted horn: install upper frame
bracket (3), horn bracket (9), screws (5) and washers
(8).
b.
Models with side mounted horn: install upper frame
bracket (3), screws (5) and washers (8).
c.
Tighten screws to 25-35 ft-lbs (33.9-47.5 Nm).
3.
Install stabilizer link (2). Secure with screws (4). Tighten
to 25-35 ft-lbs (33.9-47.5 Nm).
4
7
9
5
8
6
1
2
3
4
sm03439
1.
Engine bracket
2.
Upper stabilizer link
3.
Upper frame bracket
4.
Screw
5.
Screw (2)
6.
Screw (2)
7.
Lock washer (2)
8.
Washer (2)
9.
Horn bracket (models with front mounted horn)
Figure 2-208. Upper Front Stabilizer Link Assembly:Typical
(XL Model Shown)
LOWER FRONT STABILIZER LINK
Removal
1.
Position motorcycle upright on suitable lift.
2.
. Remove screws (3) and stabilizer link
(1).
3.
Remove screws (4), washers (5) and lower frame bracket
(2) from frame.
Installation
1.
. Install screws (4), washers (5) and lower
frame bracket (2) to frame. Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).
2.
Install stabilizer link (1). Secure with screws (3). Tighten
to 25-35 ft-lbs (33.9-47.5 Nm).
2009 Sportster Service: Chassis 2-135
4
5
2
1
3
sm03440
1.
Lower stabilizer link
2.
Lower frame bracket
3.
Screw (2)
4.
Screw (2)
5.
Washer (2)
Figure 2-209. Lower Front Stabilizer Link Assembly:Typical
(XL Model Shown)
REAR STABILIZER LINK
Removal
1.
Position motorcycle upright on suitable lift.
2.
California vehicles: remove EVAP canister and mounting
bracket. See
4.21 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS), Charcoal Canister
3.
See
. Remove short screw (3), long screw
(4), ground strap (2), stabilizer link (1) and spacer (5).
Installation
1.
See
. Install short screw (3) through ground
strap (2) and stabilizer link (1). Thread screw into frame
on right side of motorcycle. Do not tighten at this time.
2.
Install long screw (4) through ground strap, stabilizer link
and spacer (5) into engine case.
3.
Tighten both screws to 25-35 ft-lbs (33.9-47.5 Nm).
4.
California vehicles: Install EVAP canister and mounting
bracket. See
4.21 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS), Charcoal Canister
5
4
3
2
1
sm03428
1.
Stabilizer link
2.
Grounding strap
3.
Screw
4.
Screw
5.
Spacer
Figure 2-210. Rear Stabilizer Link Assembly: Typical (XL
Model Shown)
2-136 2009 Sportster Service: Chassis
2.28
FRONT ENGINE MOUNT/ISOLATOR
REMOVAL
TOOL NAME
PART NUMBER
FAT JACK
HD-45968
1.
Position motorcycle upright on a suitable lift.
2.
XL Custom models: Remove both forward foot control
assemblies. See
MODELS EQUIPPED WITH FORWARD CONTROLS
3.
Support front of engine with FAT JACK (Part No. HD-
45968) and suitable blocks.
4.
See
. Remove screw (4) securing upper front
stabilizer link (2) to stabilizer link bracket (3).
5.
See
. Remove screw (3) securing lower front
stabilizer link (1) to stabilizer link bracket (2).
6.
. Remove screw (4) from left end of rear
stabilizer link (1) and ground strap (2). Remove spacer
(5).
NOTE
. In the next step, the engine may need to be
jacked up or down slightly to aid in removing bolt (3).
7.
See
. Remove nut (4) and bolt (3) from front
engine mount/isolator assembly.
8.
Remove screws (5) from front isolator mount (2) on left
side of motorcycle. Remove isolator mount and left front
isolator (1).
9.
Carefully pry front end of engine to the left approximately
1.0 in. (25.4 mm). Remove right front isolator (1) from
crankcase.
1
1
4
2
5
3
sm01823
1.
Isolator (2)
2.
Front isolator mount
3.
Bolt
4.
Nut
5.
Screw (2)
Figure 2-211. Front Engine Mount/Isolator: Typical (XL Model Shown)
2009 Sportster Service: Chassis 2-137
INSTALLATION
TOOL NAME
PART NUMBER
FAT JACK
HD-45968
1.
. Install both front isolators (1) in engine
mounting boss on front of crankcase. Note that each isol-
ator has a half-moon tab and fits into engine mounting
boss in only one way. Push engine to the right until right
isolator contacts frame boss.
2.
Install front isolator mount (2) over left front isolator.
3.
Install screws (5) through front isolator mount and thread
into frame. Tighten to 25-35 ft-lbs (33.9-47.5 Nm).
4.
Insert bolt (3) through front isolator/engine mount assembly
from left side. Thread nut (4) onto bolt. Tighten to 60-70
ft-lbs (81.4-95.0 Nm).
5.
. Attach lower front stabilizer link (1) to
bracket (2) with screw (3). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).
6.
See
. Attach upper front stabilizer link (2) to
bracket (3) with screw (4). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).
7.
. Install screw (4) through free end of
ground strap (2), rear stabilizer link (1), spacer (5), and
into engine crankcase. Tighten to 25-35 ft-lbs (33.9-47.5
Nm).
8.
Remove FAT JACK (Part No. HD-45968) and blocks from
under engine.
9.
XL Custom models: Install both forward foot control
assemblies. See
MODELS EQUIPPED WITH FORWARD CONTROLS
2-138 2009 Sportster Service: Chassis
2.29
REAR ENGINE MOUNT/ISOLATOR
REMOVAL
TOOL NAME
PART NUMBER
SHOP DOLLY
HD-45967
FAT JACK
HD-45968
1.
Remove seat.
2.
Open left side cover. See
.
Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)
3.
Disconnect both battery cables, negative cable first. See
4.
Remove exhaust system. See
4.16 EXHAUST SYSTEM: XR MODELS
.
5.
With the aid of a FAT JACK (Part No. HD-45968), support
motorcycle on SHOP DOLLY (Part No. HD-45967).
NOTE
Position vehicle on SHOP DOLLY so that FAT JACK may be
used (with the aid of suitable blocks) to support engine when
rear engine mount is removed.
6.
Remove sprocket cover.
a.
XL models: see
. Remove screw (6),
washer (5) and exhaust pipe clamp bracket (4).
Remove two screws (2, 3). Remove sprocket cover
(1).
b.
XR models: see
. Remove screw and
washer (2) and screws (3, 4). Remove sprocket cover
(1).
7.
Loosen rear axle and remove rear drive belt. See
.
8.
XL models equipped with passenger footrests: Remove
left passenger footrest assembly. See
.
9.
XR models: Remove left and right rider controls and
brackets. See
10. Unbolt rear brake master cylinder remote reservoir. Do
not disconnect hose from reservoir. Secure reservoir to
vehicle in an upright position, out of the way. See
2.15 REAR BRAKE MASTER CYLINDER RESERVOIR
11. Support rear fork assembly using vehicle tiedown straps.
12. See
. Remove rear fork pivot bolts (1).
13. Pull rear fork back far enough to clear rear engine mounts
and isolators.
14. California vehicles: remove EVAP canister and mounting
bracket See
4.21 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS), Charcoal Canister
15. See
. Remove screws (3, 4) securing rear
stabilizer link (1). Remove stabilizer link, ground strap (2),
and spacer (5).
16. See
. Remove screw (4) securing upper front
stabilizer link (2) to stabilizer link bracket (3).
17. See
. Remove screw (3) securing lower front
stabilizer link (1) to stabilizer link bracket (2).
18. Support rear of engine with FAT JACK and suitable blocks.
19. See
. Remove two screws (7) securing rear
isolator mount (2) to left side of frame. Remove isolator
mount and left isolator (3).
20. Remove three screws (6) securing rear pivot lockplate (5)
to rear of engine case. Remove lockplate and rear fork
pivot shaft (4).
NOTE
Engine may need to be jacked up or down slightly to aid in
removing pivot shaft.
21. Carefully pry rear end of engine to the left approximately
1.0 in. (25.4 mm). Remove right rear isolator (3) from
frame.
1
2
3
6
5
4
sm01824
1.
Sprocket cover
2.
Screw
3.
Screw
4.
Exhaust pipe clamp bracket
5.
Washer
6.
Screw
Figure 2-212. Sprocket Cover: XL Models
2009 Sportster Service: Chassis 2-139
1
2
3
4
sm05328
1.
Sprocket cover
2.
Rear screw and washer
3.
Front screw
4.
Lower screw
Figure 2-213. Sprocket Cover: XR Models
3
3
6
5
4
7
2
1
1
sm01825
5.
1.
Rear pivot lockplate
Bolt (2)
2.
6.
Rear isolator mount
Screw (3)
7.
3.
Screw (2)
Isolator (2)
4.
Rear fork pivot shaft
Figure 2-214. Rear Engine Mount/Isolator: Typical (XL Model Shown)
2-140 2009 Sportster Service: Chassis
INSTALLATION
TOOL NAME
PART NUMBER
FAT JACK
HD-45968
1.
. Install new right rear isolator (3) into
frame, lining up tabs on isolator with slots in frame. Slide
rear end of engine to the right until engine mounting boss
on rear of crankcase contacts right isolator.
2.
Slide rear fork pivot shaft (4) through engine mounting
boss.
NOTE
Engine may need to be moved slightly in one direction or
another in order to line up pivot shaft with isolator.
3.
Install rear pivot lockplate (5) over pivot shaft with ridges
on lockplate engaging flats on pivot shaft flange. Secure
to crankcase with three screws (6). Tighten to 80-120 in-
lbs (9.0-13.6 Nm).
4.
Install new left rear isolator (3) on rear fork pivot shaft.
5.
Place rear isolator mount (2) over left rear isolator, lining
up tabs on isolator with slots in isolator mount. Install
screws (7). Tighten to 25-35 ft-lbs (33.9-47.5 Nm).
6.
Remove FAT JACK (Part No. HD-45968) and blocks.
7.
See
. Attach upper front stabilizer link (2) to
bracket (3) with screw (4). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).
8.
See
. Attach lower front stabilizer link (1) to
bracket (2) with screw (3). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).
9.
See
. Install short screw (3) through ground
strap (2) and rear stabilizer link (1) into frame on right side
of motorcycle. Install long screw (4) through free end of
ground strap, stabilizer link and spacer (5) into engine
case. Tighten both screws to 25-35 ft-lbs (33.9-47.5 Nm).
10. California vehicles: Install EVAP canister and mounting
bracket. See
4.21 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS), Charcoal Canister
11. See
. Slide rear fork forward into position.
Install rear fork pivot/engine mount bolts (1). Tighten to
60-70 ft-lbs (81.4-95.0 Nm). Remove vehicle tiedown
straps supporting rear fork.
12. Install rear brake master cylinder remote reservoir. See
2.15 REAR BRAKE MASTER CYLINDER RESERVOIR
13. XL models equipped with passenger footrests: Install
left passenger footrest assembly. See
14. XR models: Install left and right rider foot controls and
brackets. See
15. Install and adjust rear drive belt and tighten rear axle. See
16. XL Models: Install sprocket cover.
a.
. Install sprocket cover (1). Secure
with two screws (2, 3). Note that long screw goes in
top hole, short screw in bottom hole. Do not tighten
screws at this time.
b.
Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).
17. XR Models: Install sprocket cover.
a.
See
. Tighten screw (2) to 30-33 ft-lbs
(40.7-44.7 Nm).
b.
Tighten screws (3, 4) to 80-120 in-lbs (9.0-13.6 Nm).
18. Install exhaust system. See
4.16 EXHAUST SYSTEM: XR MODELS
.
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
19. Connect both battery cables, positive (+) cable first. See
20. Close left side cover. See
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)
21. Install seat.
2009 Sportster Service: Chassis 2-141
2.30
THROTTLE CABLES: ALL MODELS
REMOVAL AND DISASSEMBLY
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Unplug main fuse. See
.
3.
Remove seat.
4.
Remove fuel tank. See
.
5.
XL Models:
a.
. Remove screw (3) securing left
wire harness caddy (2) to right wire harness caddy
(1). See
. Separate left
wire harness caddy from right wire harness caddy.
b.
Cut cable straps (5) securing throttle cables (4) to
right wire harness caddy. Remove and discard cable
straps.
c.
Disengage ignition coil bracket (6) uprights from frame
bosses and remove throttle cables from recess in
right wire harness caddy.
6.
. Slide rubber boot off each cable adjuster
(4).
7.
. Loosen jam nut (5) on each adjuster
(6). Turn adjusters in direction which will shorten cable
housings to minimum length.
8.
See
. Remove two screws (7) and separate
upper housing (9) from lower housing (11).
9.
Unhook ferrules (1) and cables (2, 3) from throttle control
grip (12) and lower housing (11).
10. XR Models: See
. Disengage cables from
retainer (2) on lower fork bracket. Disengage cables from
loop retainer (3) located under fuel tank.
11. Remove air cleaner assembly. See
.
12. Disconnect cables from induction module.
13. See
. Remove friction spring (8), throttle fric-
tion screw (13) and spring (5) from lower housing.
1
2
3
4
5
6
sm01214
1.
Right wire harness caddy
2.
Left wire harness caddy
3.
Screw
4.
Throttle cables
5.
Cable straps
6.
Ignition coil bracket
Figure 2-215. Wire Harness Caddy Assembly: XL Models
2-142 2009 Sportster Service: Chassis
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