Harley Davidson Sportster Models 2009. Service Repair Manual — page 4

1.3

FUEL AND OIL

FUEL

Refer to

Table 1-1

. Always use a good quality unleaded gas-

oline. Octane ratings are usually found on the pump.

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Modern service station pumps dispense a high flow of gasoline
into a motorcycle fuel tank making air entrapment and pressur-
ization a possibility.

Table 1-1. Octane Ratings

RATING

SPECIFICATION

91 (95 RON)

Pump Octane (R+M)/2

GASOLINE BLENDS

Your motorcycle was designed to get the best performance
and efficiency using unleaded gasoline. Most gasoline is
blended with alcohol and/or ether to create oxygenated blends.
The type and amount of alcohol or ether added to the fuel is
important.

Do not use gasoline that contains methanol. Doing so can
result in fuel system component failure, engine damage
and/or equipment malfunction. (00148a)

•

Gasoline containing METHYL TERTIARY BUTYL ETHER
(MTBE): Gasoline/MTBE blends are a mixture of gasoline

and as much as 15% MTBE. Gasoline/MTBE blends can
be used in your motorcycle.

•

ETHANOL is a mixture of 10% ethanol (Grain alcohol) and
90% unleaded gasoline. Gasoline/ethanol blends can be
used in your motorcycle if the ethanol content does not
exceed 10%.

•

REFORMULATED OR OXYGENATED GASOLINES
(RFG): Reformulated gasoline is a term used to describe
gasoline blends that are specifically designed to burn
cleaner than other types of gasoline, leaving fewer tailpipe
emissions. They are also formulated to evaporate less
when you are filling your tank. Reformulated gasolines
use additives to oxygenate the gas. Your motorcycle will
run normally using this type of gas and Harley-Davidson
recommends you use it when possible, as an aid to cleaner
air in our environment.

•

Do not use race gas or octane boosters. Use of these fuels
will damage the fuel system.

Some gasoline blends might adversely affect the starting,
driveability or fuel efficiency of the motorcycle. If any of these
problems are experienced, try a different brand of gasoline or
gasoline with a higher octane blend.

ENGINE LUBRICATION

Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)

Engine oil is a major factor in the performance and service life
of the engine. Always use the proper grade of oil for the lowest
temperature expected before the next scheduled oil change.
Refer to

Table 1-2

. Your authorized dealer has the proper oil

to suit your requirements.

If it is necessary to add oil and Harley-Davidson oil is not
available, use an oil certified for diesel engines. Acceptable
diesel engine oil designations include: CF-4, CG-4, CH-4 and
CI-4.

The preferred viscosities for the diesel engine oils in des-
cending order are: 20W50, 15W40 and 10W40.

At the first opportunity, see an authorized dealer to change
back to 100 percent Harley-Davidson oil.

Table 1-2. Recommended Engine Oils

COLD WEATHER

STARTS BELOW 50° F

(10° C)

LOWEST AMBIENT

TEMPERATURE

H-D RATING

VISCOSITY

H-D TYPE

Excellent

Below 40° F (4° C)

HD 360

SAE 10W40

H-D Multi-grade

Good

Above 40° F (4° C)

HD 360

SAE 20W50

H-D Multi-grade

Poor

Above 60° F (16° C)

HD 360

SAE 50

H-D Regular Heavy

Poor

Above 80° F (27° C)

HD 360

SAE 60

H-D Extra Heavy

HOME

1-8 2009 Sportster Service: Maintenance

WINTER LUBRICATION

In colder climates, the engine oil should be changed often. If
motorcycle is used frequently for short trips, less than 15 miles
(24 kilometers), in ambient temperatures below 60° F (16° C),
oil change intervals should be reduced to 1500 miles (2400
kilometers). Motorcycles used only for short runs must have a
thorough tank flush-out before new oil is put in. The tank flush-
out should be performed by an authorized dealer or qualified
technician.

NOTE

The further below freezing the temperature drops, the shorter
the oil change interval should be.

Water vapor is a normal by-product of combustion in any
engine. During cold weather operation, some of the water vapor
condenses to liquid form on the cool metal surfaces inside the
engine. In freezing weather this water will become slush or ice
and, if allowed to accumulate too long, may block the oil lines
and cause damage to the engine.

If the engine is run frequently and allowed to thoroughly warm
up, most of this water will become vapor again and will be
blown out through the crankcase breather.

If the engine is not run frequently and allowed to thoroughly
warm up, this water will accumulate, mix with the engine oil
and form a sludge that is harmful to the engine.

HOME

2009 Sportster Service: Maintenance 1-9

1.4

MAINTENANCE SCHEDULE

GENERAL

The table below lists the periodic maintenance requirements
for Sportster model motorcycles. If you are familiar with the
procedures, just refer to the table for the recommended service
interval. If necessary, see the quick reference table (

Table 1-4

.)

for the required specifications.

If more detailed information is needed, turn to the sections
which follow for step-by-step instructions.

Also, throughout this manual, you will be instructed to use
various lubricants, greases and sealants. Refer to

Table 1-5

.

for the correct part numbers of these items.

Table 1-3. Regular Service Intervals: 2009 Sportster Models

NOTES

25,000 MI

40,000 KM

20,000 MI

32,000 KM

15,000 MI

24,000 KM

10,000 MI

16,000 KM

5000 MI

8000 KM

1000 MI

1600 KM

PROCEDURE

ITEM SERVICED

3

X

X

X

X

X

X

Replace

Engine oil and filter

1, 3

X

X

X

X

X

X

Inspect for leaks

Oil lines and brake system

X

X

X

X

X

X

Inspect, service as required

Air cleaner

X

X

X

X

X

X

Check pressure, inspect tread

Tires

1, 4

X

X

X

Check tightness

Wheel spokes

X

X

X

Replace

Transmission lubricant

1

X

X

X

X

X

X

Check adjustment

Clutch

X

X

X

X

X

X

Check adjustment

Primary chain

1

X

X

X

X

X

X

Inspect, adjust belt

Rear belt and sprockets

1

X

X

X

X

X

X

Check, adjust and lubricate

Throttle, brake and clutch controls

1

X

X

X

Inspect and lubricate

Jiffy stand

1

X

X

X

X

X

X

Inspect for leaks

Fuel lines and fittings

1

X

Replace

Fuel tank filter screen

5

X

X

X

X

X

X

Check levels and condition

Brake fluid

X

X

X

X

X

X

Inspect for wear

Brake pads and discs

1, 2

X

X

X

X

Inspect

Front brake lever pin

1, 2

X

Lubricate

1, 2

X

X

X

X

Inspect

Brake caliper pins

1, 2

X

Lubricate

1, 2

X

X

X

X

Inspect

Brake caliper boots and bushings

1, 2

X

Replace

1, 2

X

X

X

X

X

Inspect

Rear master cylinder outer boot

1, 2

X

Replace brake rubber components
in master cylinders and calipers

Brake components

1, 2

X

Lubricate master cylinder pistons

X

X

X

X

Inspect

Spark plugs

X

Replace

X

X

X

X

X

X

Check operation

Electrical equipment and switches

1

X

X

X

X

X

X

Check adjustment

Engine idle speed

1, 6

Replace

Front fork oil

1, 7

X

X

Adjust

Steering head bearings

1

Inspect every 30,000 MI (48,000 KM)

Rear fork bearings

1

X

X

X

X

X

X

Inspect

Shock absorbers

1

X

X

X

Check tightness

Critical fasteners

1

X

X

Inspect

Engine mounts and stabilizer links

3

Check battery and clean connections

Battery

3

X

X

X

X

X

X

Inspect for leaks, cracks, and loose
or missing fasteners or heat shields

Exhaust system

HOME

1-10 2009 Sportster Service: Maintenance

Table 1-3. Regular Service Intervals: 2009 Sportster Models

NOTES

25,000 MI

40,000 KM

20,000 MI

32,000 KM

15,000 MI

24,000 KM

10,000 MI

16,000 KM

5000 MI

8000 KM

1000 MI

1600 KM

PROCEDURE

ITEM SERVICED

X

X

X

X

X

X

Verify component and system func-
tions

Road test

1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are
mechanically qualified.

NOTES:

2. Replace every four (4) years.
3. Perform annually or at specified intervals, whichever comes first.
4. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.
5. Replace D.O.T. 4 HYDRAULIC BRAKE FLUID and flush system every two (2) years.
6. Disassemble, lubricate and inspect every 50,000 miles (80,000 km).
7. Disassemble, lubricate and inspect every 30,000 miles (48,000 km).

Table 1-4. Quick Reference Maintenance Chart

DATA

SPECIFICATION

ITEM SERVICED

2.8 qt (2.65 L)

Oil capacity

Engine oil and filter

Hand tighten 1/2-3/4 turn after gasket
contact

Filter

Part no. 63796-77A

Chrome filter (XL 1200C)

Part no. 63805-80A

Black filter (all except XL 1200C)

1/4-3/8 in. (6.3-9.5 mm)

Deflection with hot engine

Primary chain tension

3/8-1/2 in. (9.5-12.7 mm)

Deflection with cold engine

20-25 ft-lbs (27.1-33.9 Nm)

Chain tensioner nut torque

84-120 in-lbs (9.5-13.6 Nm)

Primary chain inspection cover screw
torque

32 oz. (946 mL)

Lubricant capacity

Primary chain/transmission lubricant

14-30 ft-lbs (19.0-40.7 Nm)

Primary chaincase drain plug torque

Genuine Harley-Davidson Formula+
Transmission and Primary Chaincase
Lubricant

Lubricant

1/4 turn

Free play at adjuster screw

Clutch adjustment

1/16-1/8 in. (1.6-3.2 mm)

Free play at hand lever

84-108 in-lbs (9.5-12.2 Nm)

Clutch inspection cover screw torque

Front: 30 psi (207 kPa),

Pressure for solo rider: XL Models

Tire condition and pressure

Rear: 36 psi (248 kPa)

Front: 30 psi (207 kPa),

Pressure for rider and passenger: XL
Models

Rear: 40 psi (276 kPa)

Front: 36 psi (248 kPa),

Pressure for solo rider: XR Models

Rear: 38 psi (262 kPa)

Front: 36 psi (248 kPa),

Pressure for rider and passenger: XR
Models

Rear: 42 psi (290 kPa)

Replace tire if 1/32 in. (0.8 mm) or less of
tread pattern remains

Wear

55 in-lbs (6.2 Nm)

Spoke nipple torque

Wheel spokes

SPECIAL PURPOSE GREASE

Lubricant for neck fitting

Steering head bearings

HOME

2009 Sportster Service: Maintenance 1-11

Table 1-4. Quick Reference Maintenance Chart

DATA

SPECIFICATION

ITEM SERVICED

D.O.T. 4 brake fluid

Brake fluid type

Brake fluid reservoir level

1/4 in. (6.35 mm) from the top of the
reservoir

Proper fluid level (front brake)

Upper fluid level in reservoir

Proper fluid level (rear brake)

9-17 in-lbs (1.0-2.0 Nm)

Front master cylinder reservoir cover
screw torque

0.04 in. (1.02 mm)

Minimum brake pad thickness

Brake pad linings and discs

See stamp on side of disc

Minimum brake disc thickness

10 lb. (4.5 kg)

Upward measurement force applied at
midpoint of bottom belt strand

Drive belt

XL 883C/XL 883L/XL 1200C/XL 1200L/XL
1200N: 1/4-5/16 in. (6.35-7.94 mm)

Belt deflection with motorcycle on jiffy
stand, belt and sprockets at ambient tem-
perature (cold engine), without rider or
luggage

XL 883/XL 883R/XL 1200R: 9/16-5/8 in.
(14.3-15.9 mm)

XR Models: 1/4-3/8 in. (6.4-9.5 mm)

Belt deflection measurement taken midway
between rear sprocket and idler

See

1.25 AIR CLEANER: XR MODELS

Air cleaner

40-60 in-lbs (4.5-6.8 Nm)

Air filter element screw torque: XL Models

36-60 in-lbs (4.1-6.8 Nm)

Air cleaner cover screw torque: XL Models

950-1050 RPM

Idle speed

Engine idle speed

40-45 in-lbs (4.5-5.1 Nm)

Fuel pump module mounting screw torque

Fuel filter

SUPER OIL

Lubricant

Clutch and throttle cables

108-132 in-lbs (12.2-14.9 Nm)

Handlebar clamp screw torque

35-45 in-lbs (4.0-5.1 Nm)

Handlebar switch housing screw torque

6R12

Type

Spark plugs: XL models

0.038-0.043 in. (0.96-1.09 mm)

Gap

12-18 ft-lbs (16.3-24.4 Nm)

Torque

10R12X

Type

Spark plugs: XR models

0.032-0.038 in. (0.81-0.97 mm)

Gap

12-18 ft-lbs (16.3-24.4 Nm)

Torque

HYDRAULIC FORK OIL (TYPE E)

Type

Front fork oil

See

1.22 FRONT FORK OIL

Amount

ELECTRICAL CONTACT LUBRICANT

Lubricant

Battery

60-70 in-lbs (6.8-7.9 Nm)

Terminal screw torque

See

1.33 CRITICAL FASTENERS

Critical fasteners

See

2.28 FRONT ENGINE MOUNT/ISOLATOR

,

2.29 REAR ENGINE

MOUNT/ISOLATOR

,

2.27 STABILIZER LINKS

Engine mounts/isolators and Stabilizers

HOME

1-12 2009 Sportster Service: Maintenance

Table 1-5. Lubricants, Greases, Sealants

PACKAGE

PART NUMBER

ITEM

1 oz squeeze tube

98960-97

Anti-Seize Lubricant

squeeze packet

42830-05 (included in master cylinder
rebuild kit)

CCI #20 Brake Grease

12 oz. bottle

99953-99A

D.O.T. 4 Brake Fluid

1 oz squeeze tube

99861-02

Electrical Contact Lubricant

1 qt bottle

99851-05

Genuine Harley-Davidson Formula+
Transmission and Primary Chaincase
Lubricant

squeeze packet

42820-04

G40M Brake Grease

1.9 oz squeeze tube

99650-02

Gray High Performance Sealant

3.5 oz tube

99653-85

HYLOMAR Gasket and Thread Sealant

6 ml squeeze tube

99818-97

Loctite Pipe Sealant With Teflon 565

Loctite Prism Primer (770)

Loctite Prism Superbonder (411)

Loctite Superbonder 420 Adhesive

6 ml squeeze tube

99642-97

Loctite Threadlocker 243 (blue)

6 ml squeeze tube

94759-99

Loctite Threadlocker 262 (red)

10 ml bottle

98618-03

Loctite Threadlocker 272

14 oz. cartridge

99857-97

Special Purpose Grease

1/4 fl. oz

94968-85TV

Super Oil

16 oz bottle

99884-80

Type "E" Hydraulic Fork Oil

HOME

2009 Sportster Service: Maintenance 1-13

1.5

BULB REQUIREMENTS

BULB CHART

Table 1-6. Bulb Chart: 2009 Sportster Models

HARLEY-DAVIDSON

PART NUMBER

CURRENT

DRAW

(AMPERAGE)

BULBS

REQUIRED

DESCRIPTION
(ALL LAMPS 12 VOLT)

LAMP

68329-03

5.0/4.58

1

high beam/low beam

Headlamp

53438-92

0.32

1

position lamp international

68167-04

0.59

1

tail lamp

Tail and stop lamps

68167-04

2.10

1

stop lamp

68167-04

0.59

1

tail lamp international

68167-04

2.10

1

stop lamp international

68168-89A

2.25/0.59

2

front/running

Turn signal lamp

68163-84

1.75

2

front international

68572-64B*

2.25

2

rear

68163-84**

1.75

2

rear international

Illuminated with LEDs. Replace entire assembly upon failure.

Instrument panel

*Functions as turn signals, tail lamps and brake lamps on 1200N models.
**On international and Japanese 1200N models, this is an LED assembly (replace entire assembly upon failure).

HOME

1-14 2009 Sportster Service: Maintenance

1.6

ENGINE OIL AND FILTER

CHECKING AND ADDING OIL

Check engine oil level in oil tank and add oil if necessary. Oil
tank capacity (wet) is 2.8 quarts (2.65 liters). Refer to

Table 1-2

for recommended engine oil viscosity.

Oil level cannot be accurately measured on a cold engine.
For pre-ride inspection, with motorcycle leaning on jiffy
stand on level ground, oil should register on dipstick
between arrows when engine is cold. Do not add oil to
bring the level to the FULL mark on a COLD engine.
(00185a)

Removing and Replacing Oil Filler Cap

1.

See

Figure 1-1

. Position motorcycle so that it is leaning

on jiffy stand on level ground. Remove filler cap from oil
tank on right side of vehicle.

a.

Press straight down on filler cap and release. Cap
will pop up.

b.

Pull up on filler cap while turning counterclockwise
one-quarter turn as if removing filler cap.

2.

Wipe attached dipstick clean.

NOTE

See

Figure 1-2

. Note that dipstick has a wide slot (1) and a

narrow slot (2) and can only be inserted in oil tank one way.

3.

Insert dipstick into tank. Turn filler cap clockwise one-
quarter turn as if screwing filler cap into tank. When filler
cap stops turning, it is fully seated. Press down on filler
cap until it snaps in place, flush with top of oil tank cover.

sm03751

Figure 1-1. Filler Cap/Dipstick Location

1

2

sm01412

1.

Wide slot

2.

Narrow slot

Figure 1-2. Filler Cap/Dipstick

Checking Oil with Cold Engine

1.

Position motorcycle so that it is leaning on jiffy stand on
level ground.

2.

Remove filler cap. See Removing and Replacing Oil Filler
Cap above. Wipe attached dipstick clean. Reinstall oil filler
cap in tank.

3.

Remove oil filler cap again and check oil level on dipstick.
See

Figure 1-3

. Dipstick has two marks. If oil level is at or

below lower mark (2), add only enough oil to bring the
level to a point between the two arrows on the dipstick.
Replace filler cap.

Checking Oil with Warm Engine

1.

Run engine until engine oil is at normal operating temper-
ature. Turn engine off.

2.

Position motorcycle so that it is leaning on jiffy stand on
level ground.

3.

Remove filler cap. See Removing and Replacing Oil Filler
Cap above. Wipe attached dipstick clean. Reinstall oil filler
cap in tank.

4.

Remove filler cap again and check warm oil level on dip-
stick. See

Figure 1-3

. Dipstick has two marks. If oil level

in tank is at or below lower mark, add 1.0 quart (0.946
liter) of Harley-Davidson oil to tank. Replace filler cap.

5.

If you added oil in step 4, remove filler cap and verify cor-
rect engine oil level in oil tank. Do not fill oil tank to a level
above upper mark on dipstick. Replace filler cap.

Do not overfill oil tank. Doing so can result in oil carryover
to the air cleaner leading to equipment damage and/or
equipment malfunction. (00190a)

HOME

2009 Sportster Service: Maintenance 1-15

VALVE SPRING TESTER (Part No. HD-96796-47).
Compare with

3.2 SPECIFICATIONS

. If spring length is

shorter than specification, or if spring compression force
is below specification, replace spring.

sm01520

Figure 3-121. Checking Spring Free Length

Spark Plug Threads

Inspect spark plug threads for damage. If threads in cylinder
head are damaged, a special plug type insert can be installed
using a 12 mm spark plug repair kit.

Push Rods

Examine push rods, particularly the ball ends. Replace any
rods that are bent, worn, discolored, or broken.

REPLACING ROCKER ARM BUSHINGS

TOOL NAME

PART NUMBER

ROCKER ARM BUSHING REAMER

HD-94804-57

1.

See

Figure 3-122

. To replace worn bushings, press or

drive them from the rocker arm. If bushing is difficult to
remove, turn a 9/16-18 tap into bushing. From opposite
side of rocker arm, press out bushing and tap using a
discarded rocker arm shaft.

2.

Press replacement bushing into rocker arm, flush with
rocker arm end, and split portion of bushing towards top
of rocker arm.

3.

Using remaining old bushing as a pilot, line ream new
bushing with ROCKER ARM BUSHING REAMER (Part
No. HD-94804-57).

4.

Repeat for other end of rocker arm.

sm01521

Figure 3-122. Replacing Rocker Arm Bushings

HOME

2009 Sportster Service: Engine 3-103

REPLACING VALVE GUIDES

TOOL NAME

PART NUMBER

VALVE GUIDE REAMER

B-45523

VALVE GUIDE REMOVER/INSTALLER

B-45524

VALVE GUIDE HONE

B-45525

VALVE GUIDE CLEANING BRUSH

HD-34751

CYLINDER HEAD SUPPORT STAND

HD-39782-A

CYLINDER HEAD HOLDING FIXTURE

HD-39786

REAMER T-HANDLE

HD-39847

REAMER LUBRICANT

HD-39964

Valve guide replacement, if necessary, must be done before
valve seat is ground. It is the valve stem bore in valve guide
that determines valve seat grinding location. Valve stem-to-
valve guide clearances are listed in

Table 3-32

. If valve stems

and/or valve guides are worn beyond service wear limits, install
new parts.

Removal

NOTES

•

Cylinder head support stand keeps valve guide and valve
seat perpendicular. If perpendicularity is not achieved, the
cylinder head valve guide bore will be damaged during
the press procedure.

•

Lock ring is present on OEM intake and exhaust valve
guides on XR models only.

1.

See

Figure 3-123

. Prepare cylinder head for valve guide

replacement.

a.

XR models: Remove and discard lock ring from valve
guide groove.

b.

Insert sleeve of intake (4 or 6) or exhaust (5 or 7) seat
adapter into tube at top of CYLINDER HEAD SUP-
PORT STAND (Part No. HD-39782-A) (3).

c.

Position cylinder head so that valve seat is centered
on seat adapter.

NOTE

Do not press out the valve guide from the bottom of the cylinder
head. Carbon buildup on the combustion chamber side of the
valve guide can deeply gouge the cylinder head bore dimin-
ishing the likelihood of achieving the proper interference fit and
possibly requiring replacement of the cylinder head casting.

2

1

3

6

7

5

4

sm01522

1.

Valve guide remover/installer

2.

Installer sleeve

3.

Cylinder head support stand

4.

Intake seat adapter, 883

5.

Exhaust seat adapter, 883

6.

Intake seat adapter, 1200

7.

Exhaust seat adapter, 1200

Figure 3-123. Valve Guide Replacement Tools

Table 3-32. Valve Stem Clearance/Service Wear Limits

SERVICE WEAR

LIMIT

CLEARANCE

VALVE

0.0035 in. (0.0965 mm)

0.001-0.003 in. (0.0254-0.0762 mm)

Intake

0.0035 in. (0.0965 mm)

0.001-0.003 in. (0.0254-0.0762 mm)

Exhaust

HOME

3-104 2009 Sportster Service: Engine