Harley Davidson Sportster Models 2009. Service Repair Manual — page 19
1
5
3
9
10
6
17
16
18
13
11
14
6
7
2
4
8
12
15
sm05431
10.
1.
Brake disc
E-clip
2.
11.
Screw (5)
Valve cap
12.
3.
Axle
Washer
4.
13.
Washer (5)
Valve stem
14.
5.
Hub spacer
Axle nut
6.
15.
Roller bearing (2)
Screw (5)
16.
7.
Wheel assembly, disc: XL models
Sprocket
8.
17.
Spacer, wide
Wheel assembly, cast: XL models
18.
9.
Wheel assembly, cast: XR models
Spacer, narrow
Figure 2-12. Cast or Disc Rear Wheel
2-22 2009 Sportster Service: Chassis
2
16
17
13
11
10
9
3
5
1
15
6
18
14
6
7
4
8
12
20
21
19
sm01780
12.
1.
Axle
E-clip
2.
13.
Screw (5)
Valve stem nut
14.
3.
Hub spacer
Spacer
4.
15.
Washer (5)
Brake disc screw (5)
16.
5.
Rim, standard (all except XL 883C/XL 1200C)
Axle nut
6.
17.
Roller bearing (2)
Wheel assembly, 16 in., standard rim
18.
7.
Hub
Sprocket
8.
19.
Spacer, wide
Spoke and nipple (40)
20.
9.
Rim, profile (XL 883C/XL 1200C only)
Spacer, narrow
10.
21.
Brake disc
Wheel assembly, 16 in., profile rim
11. Valve cap
Figure 2-13. Laced Rear Wheel
2009 Sportster Service: Chassis 2-23
Installation
1.
or
. Apply a light coat of ANTI-
SEIZE LUBRICANT to the axle (12), bearing (6) bores,
and hub spacer (14) bore.
2.
Place wheel centrally in the rear fork assembly. Engage
the brake disc in the caliper on XL models.
3.
XR Models: With the wheel as far forward as possible,
install the caliper/bracket assembly in place, engaging the
brake disk and the boss on the rear fork.
4.
Slide wheel forward and slip belt over sprocket and then
slide the wheel back.
5.
Position sprocket side spacer (8) between wheel and rear
fork.
6.
Insert axle (12) through right side of rear fork and right
side axle adjuster, sprocket side spacer (8), wheel
assembly, disc side spacer (9), rear caliper bracket, and
left side of rear fork and left side axle adjuster.
7.
Install washer (3) and axle nut (5) on left end of axle. Do
not tighten nut at this time.
8.
XL Models: Slide right lower shock absorber screw back
in place. Install nut and tighten to 45-50 ft-lbs (61-68 Nm).
NOTE
If rear brake caliper was disassembled or removed, see
2.16 REAR BRAKE CALIPER: XL MODELS
for the proper assembly and
installation procedure.
9.
Check for proper belt tension and rear wheel alignment.
See
.
Do not exceed specified torque when tightening axle nut.
Exceeding torque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious
injury. (00408e)
10. Tighten axle nut to 95-105 ft-lbs (129-142 Nm). Install e-
clip.
Check wheel bearing end play after tightening axle nut to
specified torque. Excessive end play can adversely affect
stability and handling. Insufficient end play can cause
bearing seizure. Either condition can cause loss of control,
which could result in death or serious injury. (00285a)
11. Check wheel bearing end play. See
.
12. XL Models: Install rear muffler. See
.
Whenever a wheel is installed and before moving the
motorcycle, pump brakes to build brake system pressure.
Insufficient pressure can adversely affect brake perform-
ance, which could result in death or serious injury.
(00284a)
13. Pump brake pedal to move piston out until it contacts
outside brake pad. Verify piston location against pad.
SEALED WHEEL BEARINGS
TOOL NAME
PART NUMBER
WHEEL BEARING
INSTALLER/REMOVER
HD-44060-B
Inspection
1.
Inspect the play of the wheel bearings by finger while they
are in the wheel. Rotate the inner bearing race and check
for abnormal noise. Make sure bearing rotates smoothly.
2.
Check wheel bearings and axle spacers for wear and
corrosion. Excessive play or roughness indicates worn
bearings. Replace bearings in sets only.
2-24 2009 Sportster Service: Chassis
3
6
7
8
9
14
13
15
11
10
5
4
12
2
1
16
sm03596
Figure 2-14. Wheel Bearing Remover/Installer (HD-44060-B) (See Table)
Table 2-15. HD-44060-B Wheel Bearing Remover/Installer
PART NO.
DESCRIPTION
NO.
HD-44060-5
Bridge
1
12547
Steel ball
2
HD-44060-4
6 in. forcing screw
3
222413
1/2-20 UNF nut
4
12004
Washer
5
280856
11 in. forcing screw
6
HD-44060-1
Support plate
7
HD-44060-8
Pilot, 1 in. and 25 mm
8
HD-44060-6
Pilot, 3/4 in.
9
HD-44060-7A
Collet, 1 in.
10
HD-44060-3A
Collet, 3/4 in.
11
J-23444-A
Thread lubricant
12
217801
Bearing
13
215654
1/2-13 UNC nut
14
HD-44060-10
Collet, 25 mm
15
HD-44060-11
Collet, 25 mm (ABS only)
16
Removal
1.
If not already done, remove wheel from motorcycle. See
. On models with a single front brake caliper,
remove hub plate from wheel on side opposite front brake
disc.
NOTE
See
. Some wheel hubs may not provide adequate
support for the puller bridge. In these cases, center a used
brake disc over the hub to support the puller bridge while
removing the bearing.
2009 Sportster Service: Chassis 2-25
SM03870
Figure 2-15. Brake Disk as Puller Aid
2.
See
. Obtain WHEEL BEARING
INSTALLER/REMOVER (Part No. HD-44060-B) and
assemble.
a.
Sparingly apply graphite lubricant to threads of forcing
screw (1) for prolonged service life and smooth
operation.
b.
Install nut (2), washer (3) and Nice bearing (4) on
screw. Insert assembly through hole in bridge (5).
c.
Drop ball bearing inside collet (6). Fasten collet and
ball bearing to forcing screw.
3.
Hold end of forcing screw and turn collet to expand edges
of collet.
4.
See
. When expanded collet has gripped
bearing edges, hold end of forcing screw (1) and turn the
nut (2) to remove bearing from wheel.
5.
Remove spacer from inside wheel hub.
6.
Repeat procedure for opposite side bearing. Discard both
bearings upon removal.
3
1
6
2
4
5
sm01685
1.
Forcing screw
2.
Nut
3.
Washer
4.
Nice bearing
5.
Bridge
6.
Collet with ball bearing inside
Figure 2-16. Wheel Bearing Removal Tool
2
1
sm01686
1.
Forcing screw
2.
Nut
Figure 2-17. Removing Bearing
2-26 2009 Sportster Service: Chassis
Installation
NOTES
•
When installing wheel bearings, use specialty tool WHEEL
BEARING INSTALLER/REMOVER (Part No. HD-44060-
B).
•
Always install first bearing on primary brake disc side. If
front wheel has two brake discs, install bearing on the left
side first.
1.
See
. Obtain WHEEL BEARING
INSTALLER/REMOVER (Part No. HD-44060-B) and
assemble.
a.
Sparingly apply graphite lubricant to threads of
threaded rod (6) for prolonged service life and smooth
operation.
b.
See
. Place threaded rod (1) through
support plate (2). Insert assembly through wheel.
c.
See
. Place new bearing on rod (1) with
lettered side facing out.
d.
Install pilot (5), Nice bearing (4), washer (3) and nut
(2) over rod.
2.
Hold hex end of threaded rod and turn nut to install wheel
bearing. Bearing is fully seated when nut can no longer
be turned. Remove tool.
3.
Install spacer inside wheel hub.
4.
Reverse tool and install opposite side wheel bearing.
5.
On cast front wheels with single brake caliper, apply two
drops of LOCTITE THREADLOCKER 243 to hub plate
mounting screws. Install hub plate opposite brake disc
and secure with screws. Tighten to 16-24 ft-lbs (21.7-32.6
Nm).
1
2
sm01783
1.
Threaded rod
2.
Support plate
Figure 2-18. Assembling Installation Tool
4
5
6
1
2
3
sm01688
1.
Threaded rod
2.
Nut
3.
Washer
4.
Nice bearing
5.
Pilot
6.
Wheel bearing
Figure 2-19. Installing Bearing
2009 Sportster Service: Chassis 2-27
2.5
WHEEL LACING: 16 INCH RIM
GENERAL
NOTES
•
If only rim is to be replaced, tape spokes together to hold
position on hub and remove spokes from rim. Install taped
hub/spoke assembly to new rim and tighten spokes. Then
remove tape and true wheels.
•
Do not install incorrect spokes or spoke nipples on rim.
. Measure spoke length (distance "A"). To
determine correct spoke length for type of rim used, refer to
.
sm02258
Figure 2-20. Measuring Spoke Length
Table 2-16. Rim Spoke Length
MM
IN.
RIM
170.4-171.5
6.71-6.75
Steel laced
173.7-174.8
6.84-6.88
Chrome aluminum
profile laced
1
2
sm02259
1.
Narrow flange (brake side)
2.
Wide flange (sprocket side)
Figure 2-21. Rim, Hub and Spoke Nipple
PROCEDURE
NOTE
The primary brake disc side of the hub can be identified by
having one or two grooves cut into the disc mounting surface.
1.
See
. Place hub on table with primary brake
disc side up. Insert a spoke in each hole of lower row as
shown in the figure. Angle spokes clockwise.
sm02261
Figure 2-22. Hub: Primary Brake Disc Side Up
2.
See
. Center rim over hub assembly with valve
stem hole facing upward.
3.
Using any lower row spoke, place first spoke into rim hole
to left of valve stem hole on upper half of rim centerline.
sm02262
Figure 2-23. Brake Side Up: Start First Spoke of Bottom
Row
4.
. Install remaining lower row spokes, one
in every fourth hole.
2-28 2009 Sportster Service: Chassis
sm02260
Figure 2-24. Brake Side Up: Bottom Row of Spokes Laced
5.
. Place first upper row spoke into hub as
shown. Angle spoke counterclockwise, crossing four
lower row spokes. Spoke must enter hole to left of valve
stem hole.
sm02263
Figure 2-25. Brake Side Up: Start First Spoke of Top Row
6.
See
. Install remaining nine upper row spokes
into every fourth remaining hole above rim centerline. This
completes spoke installation on brake disc side.
sm02264
Figure 2-26. Brake Side Up: Top Row of Spokes Laced
7.
. Turn wheel assembly over so primary
brake disk side faces down. Place any lower row spoke
into hub. Angle spoke clockwise and place into rim hole
angled to accept it.
sm02265
Figure 2-27. Sprocket Side Up: Start First Spoke of Bottom
Row
8.
. Place remaining nine lower row spokes,
angled clockwise, into hub and rim.
2009 Sportster Service: Chassis 2-29
sm02266
Figure 2-28. Sprocket Side Up: Bottom Row of Spokes
Laced
9.
. Insert any upper row spoke into hub and
angle spoke counterclockwise. Place spoke into appro-
priate rim hole.
sm02267
Figure 2-29. Sprocket Side Up: Start First Spoke of Top
Row
10. See
. Install remaining nine upper row spokes.
sm02268
Figure 2-30. Wheel Completely Laced
11. Tighten spoke nipples to specification listed in
12. True wheel. See
.
Table 2-17. Spoke Nipple Torque Specification
MINIMUM TORQUE
RIM TYPE
55 in-lbs (6.2 Nm)
All
2-30 2009 Sportster Service: Chassis
2.6
WHEEL LACING: 19 INCH RIM
PROCEDURE
NOTE
If only rim is to be replaced, tape spokes together to hold pos-
ition on hub and remove spokes from rim. Install taped
hub/spoke assembly to new rim and tighten spokes. Then
remove tape and true wheels.
1.
Divide spokes into two groups.
a.
Inner spokes have long heads.
b.
Outer spokes have short heads.
2.
Lubricate spoke threads and nipple shoulders with tire
mounting lubricant.
NOTE
The primary brake disc side of the hub can be identified by
having one or two grooves cut into the disc mounting surface.
3.
See
. Place hub on bench with the primary
brake disc side up. Insert one outer spoke (short head)
into any bottom flange hole and swing it clockwise. Insert
an inner spoke (long head) in the next hole to the left of
the outer spoke. Swing the inner spoke counterclockwise
over the outer spoke.
4.
Find the hole in the upper flange directly above the two
spokes just inserted. This hole uses a long head inner
spoke. Insert inner spoke into the hole on the upper flange
that directly bisects the two spokes in the bottom flange.
Insert all remaining spokes in upper flange alternating the
inner and outer spokes.
5.
After one flange side is completed flip wheel hub upside
down and repeat to finish other flange.
6.
. With all forty spokes inserted in hub,
group all spokes on top flange into two bundles. Secure
each group with throttle grips to keep the spokes together.
2
1
sm02245
1.
Outer spoke (short head)
2.
Inner spoke (long head)
Figure 2-31. Lacing 19 Inch Wheel Hub
sm02246
Figure 2-32. Bundling Top Spokes
7.
Swing all bottom flange outer spokes (short head) clock-
wise.
8.
Swing the inner spokes (long head) counterclockwise,
crossing over the outer spokes (short head).
9.
Angle all spokes as far as they will go without overlapping
the next LIKE spoke. For instance, swing an inner spoke
(long head) counter clockwise across four spokes as far
as it will go before crossing another inner spoke (laced in
a cross-four pattern).
NOTES
•
All inside spokes lay over all outside spokes.
•
. The valve stem hole is centered of the
rim; you do not have to worry about choosing the correct
relationship between the rim and the hub.
10. Center the rim over the hub assembly.
NOTE
It is recommended that you lace the first spoke next to the
valve stem hole. When lacing your first spoke, place spoke
nipples through several rim holes to determine the correct
lacing direction. Only one spoke will fit into the spoke nipple
correctly. When connecting the spoke to the spoke nipple,
finger tighten two to three threads.
11. Straighten any spokes that were accidentally bumped or
moved on the bottom flange.
12. Work with the bottom flange of outer spokes (short head)
first.
13. See
. Using the spoke alignment method dis-
cussed previously, locate a hole pointing downward and
outward toward the bottom flange of outer spokes (short
head).
a.
Verify outer spoke (short head) reaches the spoke
nipple and secure spoke loosely by hand. Skip three
rim holes and repeat lacing. Follow pattern to com-
plete bottom flange outer spokes (short head).
b.
. Once you have completed lacing
the bottom row of outer spokes (short head) double
check for three empty holes in between each spoke.
2009 Sportster Service: Chassis 2-31
sm01789
Figure 2-33. Valve Stem Hole Location
sm02248
Figure 2-34. Beginning Spoke: Bottom Flange Outer
sm02249
Figure 2-35. Completed Spokes: Bottom Flange Outer
14. Work with bottom flange inner spokes (long head) next.
Choose a beginning spoke closest to the valve stem hole.
a.
See
. Each inner spoke (long head)
crosses four outer spokes (short head).
b.
See
. Verify inner spoke reaches spoke
nipple and secure spoke loosely by hand. Skip every
other hole and repeat lacing. Follow pattern to com-
plete bottom row inner spokes (long head).
15. See
. Undo each top bundle and fan the spokes
out (in a starburst pattern) around the top rim edge.
sm02250
Figure 2-36. Beginning Spoke: Bottom Flange Inner
sm02251
Figure 2-37. Completed Spokes: Bottom Flange Inner
sm02252
Figure 2-38. Fanning Top Flange Spokes
16. See
. Point all the top flange inner spokes (long
head) clockwise one at a time leaving the outer spokes
(short head) resting on the rim.
2-32 2009 Sportster Service: Chassis
NOTE
Do not knock outer spokes (short head) under inner spokes
(long head) or they will be trapped underneath the inner row
of spokes.
17. Using the spoke alignment method discussed previously,
choose a beginning spoke closest to the valve stem hole.
Start with top flange inner spokes (long head) first.
a.
See
. Verify spoke reaches spoke nipple
and secure spoke by hand. Follow pattern to complete
top flange inner spokes (long head).
b.
. Once you have completed the top
flange of inner spokes (long head) double check for
one empty hole after every third spoke.
sm02253
Figure 2-39. Setting Top Flange Inner Spokes
sm02254
Figure 2-40. Beginning Spoke: Top Flange Inner
sm02255
Figure 2-41. Completed Spokes: Top Flange Inner
18. See
. Finish with top flange outer spokes (short
head). Point the top flange outer spokes (short head)
counterclockwise and make sure each one crosses four
inner spokes before securing it to the rim.
19. See
. Verify spoke reaches spoke nipple and
secure spoke by hand. Follow pattern to complete top
flange outer spokes (short head).
20. Tighten spoke nipples to specification listed in
21. True the wheel. See
sm02256
Figure 2-42. Beginning Spoke: Top Flange Outer
2009 Sportster Service: Chassis 2-33
sm02257
Figure 2-43. Completed Spokes: Top Flange Outer
Table 2-18. Spoke Nipple Torque Specification
MINIMUM TORQUE
RIM TYPE
55 in-lbs (6.2 Nm)
All
2-34 2009 Sportster Service: Chassis
2.7
WHEEL LACING: 21 INCH RIM
GENERAL
If only rim is to be replaced, tape spokes together to hold pos-
ition on hub and remove spokes from rim. Install taped
hub/spoke assembly to new rim and tighten spokes. Then
remove tape and true wheels.
NOTE
Do not install incorrect spokes or spoke nipples on rim. Using
incorrect spokes can result in improper thread engagement
which could result in damage to rim, tubes or tire.
See
. Measure distance "A" to determine spoke
length. Refer to
to determine correct spoke length
for type of rim used.
Table 2-19. 21 Inch Rim Spoke Length
MM
IN.
RIM
239.3-240.3
9.42-9.46
Steel laced
241.8-242.8
9.52-9.56
Chrome aluminum profile
laced
sm02258
Figure 2-44. Measuring Spoke Length
PROCEDURE
1.
Divide spokes into two groups.
a.
Inner spokes have long heads.
b.
Outer spokes have short heads.
NOTE
. The spoke holes in the 21 inch wheel hub
are staggered, alternating between inner holes (nearer hub
center) and outer holes (nearer hub edge).
2
1
sm01786
1.
Outer spoke hole
2.
Inner spoke hole
Figure 2-45. Spoke Hole Pattern
2.
Lubricate spoke threads and nipple shoulders with tire
mounting lubricant.
3.
See
. Place hub on bench with the brake disc
side up. Insert one outer spoke (short-head) into an outer
top flange hole and swing it counterclockwise. Insert an
inner spoke (long-head) in the next hole to the right of the
outer spoke. Swing the inner spoke clockwise under the
outer spoke.
4.
In the same way, insert all remaining spokes in brake-side
flange alternating inner and outer spokes.
5.
After brake-side flange is completed flip wheel hub over
and repeat procedure on other flange.
1
2
sm01787
1.
Outer spoke hole
2.
Outer spoke (short head)
Figure 2-46. Lacing 21 Inch Wheel Hub
6.
See
. With all forty spokes inserted in hub,
group all spokes on top flange into two bundles. Secure
each group with throttle grips to keep the spokes together.
2009 Sportster Service: Chassis 2-35
sm01788
Figure 2-47. Bundling Top Spokes
7.
Make sure all spokes on brake-side flange are still
arranged properly and pointing in the right direction:
a.
Swing all outer spokes (short-head) clockwise.
b.
Swing the inner spokes (long-head) counterclockwise,
crossing over the outer spokes (short-head).
c.
Angle all spokes as far as they will go without overlap-
ping the next LIKE spoke. For instance, swing an
inner spoke (long-head) counterclockwise across four
spokes as far as it will go before crossing another
inner spoke (laced in a cross-four pattern).
NOTES
•
All inside spokes lay over all outside spokes.
•
See
. The valve stem hole is centered on the
rim; you do not have to worry about choosing the correct
relationship between the rim and the hub.
8.
Center the rim over the hub assembly.
sm01789
Figure 2-48. Valve Stem Hole Location
NOTE
It is recommended that you lace the first spoke next to the
valve stem hole. When lacing your first spoke, place spoke
nipples through several rim holes to determine the correct
lacing direction. Only one spoke will fit into the spoke nipple
correctly. When connecting the spoke to the spoke nipple,
finger tighten two to three threads.
9.
Straighten any spokes that were accidentally bumped or
moved on the bottom flange.
10. Work with the bottom flange of outer spokes (short-head)
first. See
. Using the spoke alignment method
discussed previously, locate a spoke hole in the rim
pointing downward and outward toward the bottom flange
of outer spokes (short-head).
a.
Verify outer spoke (short-head) reaches the spoke
nipple and secure spoke loosely by hand. Skip three
rim holes and repeat lacing. Follow pattern to com-
plete bottom flange outer spokes (short-head).
b.
. Once you have completed lacing
the bottom row of outer spokes (short-head) double
check for three empty holes in between each spoke.
sm01790
Figure 2-49. Beginning Spoke-Bottom Flange Outer
sm01791
Figure 2-50. Completed Spokes-Bottom Flange Outer
11. Work with bottom flange inner spokes (long-head) next.
Choose a beginning spoke closest to the valve stem hole.
a.
See
. Each inner spoke (long-head)
crosses four outer spokes (short-head).
b.
See
. Verify inner spoke reaches spoke
nipple and secure spoke loosely by hand. Skip every
other hole and repeat lacing. Follow pattern to com-
plete bottom row inner spokes (long-head).
2-36 2009 Sportster Service: Chassis
sm01792
Figure 2-51. Beginning Spoke-Bottom Flange Inner
sm01793
Figure 2-52. Completed Spokes-Bottom Flange Inner
12. See
. Undo each top bundle and fan the spokes
out (in a starburst pattern) around the top rim edge.
sm01794
Figure 2-53. Fanning Top Flange Spokes
13. See
. Point all the top flange inner spokes
(long-head) clockwise one at a time leaving the outer
spokes (short-head) resting on the rim.
NOTE
Do not knock outer spokes (short-head) under inner spokes
(long-head) or they will be trapped underneath the inner row
of spokes.
sm01795
Figure 2-54. Setting Top Flange Inner Spokes
14. Using the spoke alignment method discussed previously,
choose a beginning spoke closest to the valve stem hole.
Start with top flange inner spokes (long-head) first.
a.
. Verify spoke reaches spoke nipple
and secure spoke by hand. Follow pattern to complete
top flange inner spokes (long-head).
b.
. Once you have completed the top
flange of inner spokes (long-head) double check for
one empty hole after every third spoke.
sm01796
Figure 2-55. Beginning Spoke-Top Flange Inner
2009 Sportster Service: Chassis 2-37
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