Harley Davidson Sportster Models 2009. Service Repair Manual — page 1
ABOUT THIS MANUAL
GENERAL
This Service Manual has been prepared with two purposes in
mind. First, it will acquaint the user with the construction of the
Harley-Davidson product and assist in the performance of basic
maintenance and repair. Secondly, it will introduce to the pro-
fessional Harley-Davidson Technician the latest field-tested
and factory-approved major repair methods. We sincerely
believe that this Service Manual will make your association
with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
CHAPTER
NO.
Maintenance
1
Chassis
2
Engine
3
Fuel System
4
Drive/Transmission
5
Electrical
6
Appendix A Connector Repair
A
Appendix B Wiring
B
Appendix C Conversions
C
Appendix D Compensating Sprocket
D
Appendix E Glossary
E
Use the TABLE OF CONTENTS (which follows this FORE-
WORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Sections and topics in this manual are
sequentially numbered for easy navigation.
For example, a cross-reference shown as 2.1 SPECIFICA-
TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC-
ATIONS.
For quick and easy reference, all pages contain a section
number followed by a page number. For example, page 3-5
refers to page 5 in section 3.
A number of acronyms and abbreviations are used in this
document. See the
for a list of acronyms,
abbreviations and definitions.
PREPARATION FOR SERVICE
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)
Good preparation is very important for efficient service work.
A clean work area at the start of each job will allow you to
perform the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts. A motorcycle
that is excessively dirty should be cleaned before work starts.
Cleaning will occasionally uncover sources of trouble. Tools,
instruments and any parts needed for the job should be
gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay.
NOTES
•
To avoid unnecessary disassembly, carefully read all rel-
ative service information before repair work is started.
•
In figure legends, the number which follows the name of
a part indicates the quantity necessary for one complete
assembly.
•
When servicing a vehicle equipped with the Harley-Dav-
idson Smart Security System (H-DSSS), you must first
disarm the security system. Either keep the fob in close
proximity to the vehicle, or use Digital Technician II to
disable the security system while the vehicle is being ser-
viced and re-enable the system after service is completed.
SERVICE BULLETINS
In addition to the information presented in this Service Manual,
Harley-Davidson Motor Company will periodically issue Service
Bulletins to Harley-Davidson dealers. Service Bulletins cover
interim engineering changes and supplementary information.
Consult the Service Bulletins to keep your product knowledge
current and complete.
USE GENUINE REPLACEMENT PARTS
Do not use aftermarket parts and custom made front forks
which can adversely affect performance and handling.
Removing or altering factory installed parts can adversely
affect performance and could result in death or serious
injury. (00001a)
To ensure satisfactory and lasting repairs, carefully follow the
Service Manual instructions and use only genuine Harley-
Davidson replacement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting
experience. This is your assurance that the parts you are using
will fit right, operate properly and last longer.
WARNINGS AND CAUTIONS
Statements in this service manual preceded by the following
words are of special significance.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage. (00140a)
I
FOREW
ORD
NOTE
Refers to important information, and is placed in italic type. It
is recommended that you take special notice of these items.
Proper service and repair is important for the safe, reliable
operation of all mechanical products. The service procedures
recommended and described in this service manual are
effective methods for performing service operations.
Always wear proper eye protection when using hammers,
arbor or hydraulic presses, gear pullers, spring com-
pressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b)
Some of these service operations require the use of tools
specially designed for the purpose. These special tools should
be used when and as recommended. It is important to note
that some warnings against the use of specific service methods,
which could damage the motorcycle or render it unsafe, are
stated in this service manual. However, please remember that
these warnings are not all-inclusive. Inadequate safety precau-
tions could result in death or serious injury.
Since Harley-Davidson could not possibly know, evaluate or
advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous con-
sequences of each method, we have not undertaken any such
broad evaluation. Accordingly, anyone who uses a service
procedure or tool which is not recommended by Harley-Dav-
idson must first thoroughly satisfy himself that neither his nor
the operator's safety will be jeopardized as a result. Failure to
do so could result in death or serious injury.
PRODUCT REFERENCES
Read and follow warnings and directions on all products.
Failure to follow warnings and directions can result in
death or serious injury. (00470b)
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.
Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
information or product returns, warranty or otherwise, visit
www.spx.com.
Loctite Sealing and Threadlocking Products
Some procedures in this manual call for the use of Loctite
products. If you have any questions regarding Loctite product
usage or retailer/wholesaler locations, please contact Loctite
Corp. at www.loctite.com.
PRODUCT REGISTERED MARKS
Alcantara S.p.A., Allen, Amp Multilock, Bluetooth, Brembo,
Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk,
Hydroseal, Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps,
K&N, Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse,
Molex, MPZ, Mulitilock, Novus, Packard, Pirelli, Permatex,
Philips, PJ1, Pozidriv, Robinair, S100, Sems, Snap-on, Teflon,
Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch,
Velcro, X-Acto, and XM Satellite Radio are among the trade-
marks of their respective owners.
H-D MICHIGAN, INC. TRADEMARK
INFORMATION
Harley, Harley-Davidson, H-D, Bar & Shield, Cross Bones,
Digital Tech, Digital Technician, Digital Technician II, Dyna,
Electra Glide, Evolution, Fat Bob, Fat Boy, Glaze, Gloss, H-D,
H-Dnet.com, HD, Harley, Harley-Davidson, Heritage Softail,
Low Rider, Night Rod, Nightster, Night Train, Profile, Revolu-
tion, Road Glide, Road King, Road Tech, Rocker, Softail,
Sportster, Street Glide, Street Rod, Sun Ray, Sunwash, Tech
Link, Twin Cam 88, Twin Cam 88B, Twin Cam 96, Twin Cam
96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin
Cam 110B, Tour-Pak, Screamin' Eagle, Softail, Super Glide,
SYN3, Ultra Classic, V-Rod, VRSC and Harley-Davidson
Genuine Motor Parts and Genuine Motor Accessories are
among the trademarks of H-D Michigan, Inc.
CONTENTS
All photographs, illustrations and procedures may not neces-
sarily depict the most current model or component, but are
based on the latest production information available at the time
of publication.
Since product improvement is our continual goal, Harley-Dav-
idson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
obligation.
II FOREWORD
Fastener Torque Values in this Chapter. . . . . . . ..1-1
Repair and Replacement Procedures. . . . . . . . 1-5
Cleaning. . . . . . . . . . . . . . . . . . . .1-6
Tool Safety. . . . . . . . . . . . . . . . . . ..1-6
General. . . . . . . . . . . . . . . . . . . .1-10
Bulb Chart. . . . . . . . . . . . . . . . . . 1-14
Checking and Adding Oil. . . . . . . . . . . . ..1-15
Changing Oil and Filter. . . . . . . . . . . . . .1-16
General. . . . . . . . . . . . . . . . . ..1-16
1.8 BLEEDING HYDRAULIC BRAKE SYSTEM
1.9 BRAKE PADS AND DISCS: XL MODELS
Inspection. . . . . . . . . . . . . . . . . . .1-24
1.10 BRAKE PADS AND DISCS: XR MODELS
Inspection. . . . . . . . . . . . . . . . . . .1-31
Brake Pad Replacement: Front. . . . . . . . . . .1-31
Removal. . . . . . . . . . . . . . . . . 1-31
Installation. . . . . . . . . . . . . . . . .1-32
Brake Pad Replacement: Rear. . . . . . . . . . .1-33
Removal. . . . . . . . . . . . . . . . . 1-33
Installation. . . . . . . . . . . . . . . . .1-34
Inspection. . . . . . . . . . . . . . . . ..1-37
When To Replace Tires. . . . . . . . . . . .1-37
Adjustment. . . . . . . . . . . . . . . . . ...1-41
Transmission Lubrication: Sportster Models. . . . . .1-43
Check Lubricant Level. . . . . . . . . . . ...1-43
Changing Lubricant. . . . . . . . . . . . ...1-44
Rear Drive Belt: Sportster Models. . . . . . . . . 1-47
III
T
ABLE OF CONTENTS
General. . . . . . . . . . . . . . . . . ..1-47
Gauging Deflection. . . . . . . . . . . . . 1-47
Checking Wheel Alignment. . . . . . . . . ...1-49
Adjusting Wheel Alignment. . . . . . . . . ...1-50
Safety Precautions. . . . . . . . . . . . . 1-54
Using a Battery Charger. . . . . . . . . . . 1-54
1.20 SHOCK ABSORBER ADJUSTMENT
Shock Absorber Preload Adjustment: Sportster Models...1-62
Changing Fork Oil: XL Models. . . . . . . . . . ..1-65
Changing Fork Oil: XR Models. . . . . . . . . . .1-66
Left Fork. . . . . . . . . . . . . . . . . 1-67
Right Fork. . . . . . . . . . . . . . . . ..1-69
1.23 CABLE AND CHASSIS LUBRICATION
Exhaust System Leak Check. . . . . . . . . . . 1-78
1.28 IDLE SPEED AND IGNITION TIMING
1.30 ENGINE MOUNTS AND STABILIZER
LINKS
Inspection. . . . . . . . . . . . . . . . . . .1-82
1.32 FLUID AND LUBRICANT
REQUIREMENTS
Inspection. . . . . . . . . . . . . . . . . . .1-86
Checking Torques on Fasteners. . . . . . . . 1-86
Lubrication System. . . . . . . . . . . . . . ...1-91
Oil Does Not Return To Oil Tank. . . . . . . . 1-91
IV TABLE OF CONTENTS
TABLE OF CONTENTS
2.17
REAR BRAKE CALIPER: XR MODELS
REMOVAL
NOTE
If only replacing brake pads, do not remove rear brake caliper.
For brake pad replacement only, see
.
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)
NOTE
Damaged banjo bolt surfaces will leak when reassembled.
Prevent damage to seating surfaces by carefully removing
brake line components.
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTES
If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.
1.
Position vehicle upright on a suitable lift.
2.
Place a suitable container under the rear caliper brake
line banjo fitting to catch any brake fluid that may leak out.
Do not reuse brake fluid.
3.
Disconnect left shock absorber from rear fork and rotate
shock absorber out of the way.
4.
Loosen rear axle nut and turn adjuster nuts to allow the
rear wheel to move forward to the adjustment limit.
5.
. Remove the banjo bolt (2) and both
washers (3) to detach rear brake line (1) from brake cal-
iper. Discard washers.
6.
Remove mounting bolt (5) and bolt pin (6).
7.
Remove caliper assembly from motorcycle.
1
6
2
3
4
5
sm05109
1.
Rear brake line
2.
Banjo bolt
3.
Washer (2)
4.
Bleeder valve
5.
Mounting bolt
6.
Bolt pin
Figure 2-134. Rear Caliper Assembly
2-90 2009 Sportster Service: Chassis
18
1
6
2
4
19
9
17
14
13
12
11
16
15
10
3
5
8
7
7
sm05110
11.
1.
Bleeder nipple cap
Caliper mounting bracket
2.
12.
Wear plate
Pad pin
13.
3.
Pad pin plug
Piston
4.
14.
Dust seal
Mounting bolt
15.
5.
Boot
Piston seal
6.
16.
Pad spring
Bushing
17.
7.
Bolt pin
Pad retainer
8.
18.
Brake pad
Boot
19.
9.
Damper
Caliper housing
10. Bleeder valve
Figure 2-135. Rear Brake Caliper Assembly
DISASSEMBLY
1.
. Remove brake pad pin plug to expose
brake pad pin (1). Remove brake pad pin and pads (2).
2.
See
. Remove pad spring (1).
2009 Sportster Service: Chassis 2-91
3.
Remove bushing (2) from boot (3). Remove boot from
mounting hole (4). Do not remove bleeder valve at this
time.
4.
. Install a discarded brake pad (1) in the
caliper with the backing plate facing the piston. Position
the brake pad so the friction material is against the back
of the caliper, as shown.
5.
Loosely install brake pad pin (2) to hold brake pad in place.
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)
When removing piston with compressed air, piston can
develop considerable force and fly out of caliper bore.
Keep hands away from piston to avoid possible injury.
(00530b)
NOTE
Be careful not to damage banjo bolt sealing surface or threads
of banjo bolt hole in brake caliper. It is recommended that you
use an air nozzle with a rubber tip to perform the next step in
this procedure.
6.
Gently apply low pressure compressed air to banjo bolt
hole (3) to force piston from caliper bore.
7.
Remove brake pad pin and brake pad from caliper.
8.
Remove piston from caliper bore by hand. If necessary,
gently wiggle piston to completely remove.
NOTE
A damaged piston bore will leak when reassembled. Do not
use metal objects to remove or install components in piston
bore. Prevent damage to piston, seal and bore by only using
a wooden toothpick when servicing caliper.
9.
. Using a wooden toothpick (1), remove
dust seal (2) and piston seal (3) from caliper bore. Discard
seals.
10. If necessary, remove bleeder valve.
1
2
sm05112
1.
Pad pin (plug removed)
2.
Brake pad
Figure 2-136. Pad Pin
3
2
1
4
sm05113
1.
Pad spring
2.
Bushing
3.
Boot
4.
Mounting hole
Figure 2-137. Spring, Bushing and Boot
2-92 2009 Sportster Service: Chassis
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