Harley Davidson Sportster Models 2009. Service Repair Manual — page 74

C.2

FLUID CONVERSIONS

UNITED STATES SYSTEM

Unless otherwise specified, all fluid volume measurements in
this Service Manual are expressed in United States (U.S.)
units-of-measure. See below:

•

1 pint (U.S.) = 16 fluid ounces (U.S.)

•

1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)

•

1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)

METRIC SYSTEM

Fluid volume measurements in this Service Manual include
the metric system equivalents. In the metric system, 1 liter (L)
= 1,000 milliliters (mL). Should you need to convert from U.S.
units-of-measure to metric units-of-measure (or vice versa),
refer to the following:

•

fluid ounces (U.S.) x 29.574 = milliliters

•

pints (U.S.) x 0.473 = liters

•

quarts (U.S.) x 0.946 = liters

•

gallons (U.S.) x 3.785 = liters

•

milliliters x 0.0338 = fluid ounces (U.S.)

•

liters x 2.114 = pints (U.S.)

•

liters x 1.057 = quarts (U.S.)

•

liters x 0.264 = gallons (U.S.)

BRITISH IMPERIAL SYSTEM

Fluid volume measurements in this Service Manual do not
include the British Imperial (Imp.) system equivalents. The fol-
lowing conversions exist in the British Imperial system:

•

1 pint (Imp.) = 20 fluid ounces (Imp.)

•

1 quart (Imp.) = 2 pints (Imp.)

•

1 gallon (Imp.) = 4 quarts (Imp.)

Although the same unit-of-measure terminology as the U.S.
system is used in the British Imperial (Imp.) system, the actual
volume of each British Imperial unit-of-measure differs from its
U.S. counterpart. The U.S. fluid ounce is larger than the British
Imperial fluid ounce. However, the U.S. pint, quart, and gallon
are smaller than the British Imperial pint, quart, and gallon,
respectively. Should you need to convert from U.S. units to
British Imperial units (or vice versa), refer to the following:

•

fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)

•

pints (U.S.) x 0.833 = pints (Imp.)

•

quarts (U.S.) x 0.833 = quarts (Imp.)

•

gallons (U.S.) x 0.833 = gallons (Imp.)

•

fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)

•

pints (Imp.) x 1.201 = pints (U.S.)

•

quarts (Imp.) x 1.201 = quarts (U.S.)

•

gallons (Imp.) x 1.201 = gallons (U.S.)

HOME

C-2 2009 Sportster Service: Appendix C Conversions

C.3

TORQUE CONVERSIONS

UNITED STATES SYSTEM

The U.S. units of torque, foot pounds and inch pounds, are
used in this service manual. To convert units, use the following
equations:

•

foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs).

•

inch pounds (in-lbs) X 0.08333 = foot pounds (ft-lbs).

METRIC SYSTEM

All metric torque specifications are written in Newton-meters
(Nm). To convert metric to United States units and United
States to metric, use the following equations:

•

Newton meters (Nm) X 0.737563 = foot pounds (ft-lbs).

•

Newton meters (Nm) X 8.85085 = inch pounds (in-lbs).

•

foot pounds (ft-lbs) X 1.35582 = Newton meters (Nm).

•

inch pounds (in-lbs) X 0.112985 = Newton meters (Nm).

HOME

2009 Sportster Service: Appendix C Conversions C-3

D.1

COMPENSATING SPROCKET

GENERAL

Sportster models sold in the Japanese market are equipped
with a rear wheel compensating sprocket.

Periodic inspection of the compensator components is recom-
mended. This should be done any time the rear wheel is
removed.

REMOVAL AND DISASSEMBLY

1.

Remove rear wheel. See

2.4 WHEELS

.

2.

See

Figure D-1

. Remove final drive sprocket assembly

(2) and spacer (6).

3.

Pull sprocket isolators (5) from compensator bowl (7).

NOTE

Only remove compensator bowl (7) from rear wheel (8) if
necessary. Bolts (3) are one-time usage only. If removed, they
must be discarded and replaced with new bolts.

4.

If necessary, remove bolts with captive washers (3) and
compensator bowl from rear wheel (8). Discard bolts.

1

2

6

3

7

5

8

4

sm03748

1.

Sprocket bearing (part of final drive sprocket
assembly)

2.

Final drive sprocket assembly

3.

Bolt with captive washer (5)

4.

Compensator bowl casting lip

5.

Sprocket isolator (5)

6.

Spacer

7.

Compensator bowl

8.

Rear wheel

Figure D-1. Compensating Sprocket

CLEANING, INSPECTION AND REPAIR

1.

See

Figure D-1

. Wipe inside of compensator bowl (7) and

final drive sprocket (2) with a clean, damp cloth.

2.

Inspect sprocket bearing (1). If bearing surface is rough
or if bearing was leaking grease, replace bearing. See

D.1 COMPENSATING SPROCKET, Sprocket Bearing
Replacement

.

3.

Inspect sprocket isolators (5) for damage, deterioration,
missing chunks or excessive debris beyond normal wear
marks. Replace if necessary.

SPROCKET BEARING REPLACEMENT

TOOL NAME

PART NUMBER

REAR WHEEL COMPENSATOR
SPROCKET BEARING
REMOVER/INSTALLER

HD-48921

Removal

1.

Remove rear wheel. See

2.4 WHEELS, Rear Wheel

.

2.

Pull sprocket from bowl.

3.

See

Figure D-2

. Obtain the REAR WHEEL COM-

P E N S ATO R S P R O C K E T B E A R I N G
REMOVER/INSTALLER (Part No. HD-48921).

1

2

3

sm04354

1.

Base

2.

Sleeve

3.

Driver

Figure D-2. Rear Wheel Compensator Sprocket Bearing

Remover/Installer (Part No. HD-48921)

4.

See

Figure D-3

. Place parallel press blocks on deck of

arbor press. Leave gap between press blocks to accom-
modate base pin in next step.

5.

Position base (1) on press blocks with the large OD top-
side.

6.

Slide sleeve (2) over base pin.

7.

See

Figure D-4

. With the inboard side facing up, slide

sprocket (1) over sleeve until it rests on base.

8.

Slide small OD of driver (2) over sleeve until contact is
made with inner race of bearing.

9.

Center driver under ram and apply pressure until bearing
drops into base. Disassemble tool and discard bearing.

HOME

2009 Sportster Service: Appendix D Compensating Sprocket D-1

1

2

sm04355

1.

Base

2.

Sleeve

Figure D-3. Position Tool for Bearing Removal

1

2

sm04356

1.

Sprocket (inboard side up)

2.

Driver

Figure D-4. Remove Compensator Sprocket Bearing

Installation

1.

See

Figure D-2

. Obtain the REAR WHEEL COM-

P E N S ATO R S P R O C K E T B E A R I N G
REMOVER/INSTALLER (Part No. HD-48921).

2.

See

Figure D-5

. Position base (1) on deck of arbor press

with the small OD topside.

3.

Slide sleeve (2) over base pin.

4.

Verify that sprocket bearing bore is clean and dry.

5.

See

Figure D-6

. With the outboard side facing up, slide

sprocket (1) over sleeve until it rests on base.

6.

Slide bearing (2) over sleeve.

7.

Slide large OD of driver (3) over sleeve until contact is
made with outer race of bearing.

8.

Center driver under ram and apply pressure until bearing
makes firm contact with counterbore in sprocket.

9.

Turn sprocket over and verify that bearing is fully seated.

1

2

sm04358

1.

Base

2.

Sleeve

Figure D-5. Position Tool for Bearing Installation

1

2

3

sm04359

1.

Sprocket (outboard side up)

2.

Bearing outer race

3.

Driver

Figure D-6. Install Compensator Sprocket Bearing

ASSEMBLY AND INSTALLATION

NOTES

•

See

Figure D-1

. Only remove compensator bowl (7) from

rear wheel (8) if necessary. Bolts (3) are one-time usage
only. If removed, they must be discarded and replaced
with new bolts.

•

New compensator bowl bolts are equipped with a LOC-
TITE patch on the threads. Do not apply any additional
LOCTITE.

HOME

D-2 2009 Sportster Service: Appendix D Compensating Sprocket

1.

See

Figure D-1

. If compensator bowl (7) was removed,

install bowl onto rear wheel with new bolts with captive
washers (3). Tighten bolts as follows:

a.

Tighten bolts in a star pattern (every other bolt) to 60
ft-lbs (81.3 Nm).

b.

Loosen screws 1/2 turn.

c.

Retighten all five screws in the same star pattern to
80 ft-lbs (108.5 Nm).

NOTE

Do not lubricate inside of compensator bowl (7), sprocket (2)
or sprocket isolators (5) with any type of oil based lubricant.
Use ONLY soapy water or window cleaner on isolators to
facilitate their installation. Do not install isolators dry.

2.

See

Figure D-7

. Lubricate isolators (1) with soapy water

or window cleaner. Install isolators (1) into compensator
bowl (2).

NOTE

Inner spacer can be identified by a radial groove machined
into its surface. Inner spacer is also thicker than outer spacer.
Make sure to install the correct spacer between compensator
bowl and sprocket.

3.

See

Figure D-1

. Install spacer (6) by placing on bowl

casting lip (4).

NOTE

Use extreme caution to make sure that spacer does not fall
out when assembling sprocket onto compensator bowl. If
spacer is not present when rear axle is tightened, compensator
sprocket and bearing will be damaged.

4.

Install sprocket (2) onto compensator bowl (7).

5.

Install rear wheel. See

2.4 WHEELS

.

1

2

sm03749

1.

Sprocket isolator (5)

2.

Compensator bowl

Figure D-7. Installing Sprocket Isolators

HOME

2009 Sportster Service: Appendix D Compensating Sprocket D-3

E.1

GLOSSARY

ACRONYMS AND ABBREVIATIONS

Table E-1. Acronyms and Abbreviations

DESCRIPTION

ACRONYM OR ABBREVIATION

Amperes

A

Alternating Current

AC

Accessory

ACC

Automatic Compression Release

ACR

Absorbed Glass Mat (battery)

AGM

Ampere

AMP

American Wire Gauge

AWG

Battery Voltage

B+

Bank Angle Sensor

BAS

Before Top Dead Center

BTDC

Celsius (Centigrade)

C

California

CA

Calibration

CAL

Cubic Centimeters

CC

Cold Cranking Amps

CCA

Crankshaft Position

CKP

Centimeter

cm

Direct Current

DC

Data Link Connector

DLC

Domestic

DOM

Diagnostic Trouble Code

DTC

Digital Volt Ohm Meter

DVOM

Electronic Control Module

ECM

Engine Coolant Temperature

ECT

Electrically Erasable Programmable Read Only Memory

EEPROM

Electronic Fuel Injection

EFI

Engine Temperature

ET

Evaporative Emissions Control System

EVAP

Fahrenheit

F

Foot-Pounds

ft-lbs

Fluid Ounce

fl oz.

Gram

g

Gallon

GAL

Gross Axle Weight Rating

GAWR

Ground (electrical)

GND

Gross Vehicle Weight Rating

GVWR

Harley-Davidson International

HDI

Harley-Davidson Smart Security System

H-DSSS

Hands Free Security Module

HFSM

Mercury

Hg

HOME

2009 Sportster Service: Appendix E Glossary E-1

Table E-1. Acronyms and Abbreviations

DESCRIPTION

ACRONYM OR ABBREVIATION

Idle Air Control

IAC

Intake Air Temperature

IAT

Instrument Cluster

IC

Inside Diameter

ID

Ignition Light/Key Switch

IGN

Inch

In.

Injector Pulse Width

INJ PW

Inch-Pounds

in-lbs

Kilogram

Kg

Kilometer

Km

Kilopascal

kPa

Kilometers Per Hour

km/hr

Liter

L

Liquid Crystal Display

LCD

Light Emitting Diode

LED

Milliampere

mA

Manifold Absolute Pressure

MAP

milliliter

ml

millimeter

mm

Miles Per Hour

MPH

millisecond

ms

Newton-Meter

Nm

Not Applicable

N/A

Number

no.

Oxygen

O2

Outside Diameter

OD

Original Equipment Manufacturer

OEM

Ounce

oz

Parts and Accessories

P&A

Part Number

PN

Pounds per Square Inch

PSI

Pulse Width Modulated signal

PWM signal

Reserve

RES

Revolutions Per Minute

RPM

Cubic Feet per Hour at Standard Conditions

SCFH

Throttle Control Actuator

TCA

Top Dead Center

TDC

Twist Grip Sensor

TGS

Throttle Position

TP

Intake Air Temperature/Manifold Absolute Pressure

TMAP

Turn Signal Module

TSM

Turn Signal/Security Module

TSSM

Volt

V

HOME

E-2 2009 Sportster Service: Appendix E Glossary

Table E-1. Acronyms and Abbreviations

DESCRIPTION

ACRONYM OR ABBREVIATION

Volts of Alternating Current

VAC

Volts of Direct Current

VDC

Vehicle Identification Number

VIN

Vehicle Speed Sensor

VSS

HOME

2009 Sportster Service: Appendix E Glossary E-3

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

1.34 STORAGE, Placing in Storage

STORAGE COVER

98716-87A

1.17 BATTERY MAINTENANCE, Storage

GLOBAL BATTERY CHARGER

99863-01A

5.13 TRANSMISSION RIGHT CASE BEARINGS, Install-
ation

SNAP-ON BUSHING DRIVER SET

A-157C

3.21 CYLINDER HEAD, Refacing Valve Seats

CUTTER PILOT

B-35758-52A

2.22 FRONT FORK: XR MODELS, Assembly

FORK SEAL DRIVER

B-42571

2.22 FRONT FORK: XR MODELS, Assembly

FORK SEAL DRIVER

B-42571

5.10 TRANSMISSION REMOVAL AND DISAS-
SEMBLY, Transmission Removal From Left Crankcase

TRANSMISSION REMOVER

B-43895-1

5.15 TRANSMISSION INSTALLATION, Installation

TRANSMISSION REMOVAL AND
INSTALLATION TOOL

B-43985

5.15 TRANSMISSION INSTALLATION, Installation

COUNTERSHAFT GUIDE

B-43985-4

3.18 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

GEAR DETENT ASSEMBLY AID

B-45520

5.15 TRANSMISSION INSTALLATION, Assembling
Crankcases

GEAR DETENT ASSEMBLY AID

B-45520

3.21 CYLINDER HEAD, Replacing Valve Guides

VALVE GUIDE REAMER

B-45523

3.21 CYLINDER HEAD, Replacing Valve Guides

VALVE GUIDE REMOVER/INSTALLER

B-45524

3.21 CYLINDER HEAD, Cleaning and Inspection

VALVE GUIDE HONE

B-45525

3.21 CYLINDER HEAD, Replacing Valve Guides

VALVE GUIDE HONE

B-45525

3.18 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

CRANKCASE BEARING
REMOVER/INSTALLER

B-45655

3.23 CRANKCASE, Disassembly

CRANKCASE BEARING
REMOVER/INSTALLER WITH ADAPTER

B-45655, HD-42720-2,
HD-46663

3.18 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

SPROCKET SHAFT SEAL/SPACER
INSTALLER

B-45676-A

5.12 MAIN DRIVE GEAR AND BEARING, Removal

CROSS PLATE

B-45847

5.12 MAIN DRIVE GEAR AND BEARING, Installation

CROSS PLATE

B-45847

5.6 PRIMARY DRIVE AND CLUTCH: XR
MODELS, Clutch Shell Bearing Replacement

CLUTCH SHELL BEARING
REMOVER/INSTALLER

B-45926

A.2 AUTOFUSE ELECTRICAL CONNECTORS, Autofuse
Connector Repair

SNAP-ON TERMINAL PICK

GA500A

4.10 INDUCTION MODULE: XL MODELS, Disassembly

HEAT GUN

HD-25070

6.39 HANDLEBAR SWITCH ASSEMBLIES, Repair Pro-
cedures

ROBINAIR HEAT GUN

HD-25070

A.17 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

ROBINAIR HEAT GUN

HD-25070

3.7 TROUBLESHOOTING, Compression Test

CYLINDER COMPRESSION GAUGE

HD-33223-1

2.23 FORK STEM AND BRACKET ASSEMBLY, Cleaning,
Inspection and Repair

UNIVERSAL DRIVER HANDLE

HD-33416

3.22 CYLINDER AND PISTON, Cleaning, Inspection and
Repair

TORQUE PLATE BOLTS

HD-33446-86

3.22 CYLINDER AND PISTON, Cleaning, Inspection and
Repair

CYLINDER TORQUE PLATES

HD-33446-B

3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder
and Piston

PISTON PIN LOCK RING
REMOVER/INSTALLER

HD-34623-C

3.16 TOP END OVERHAUL: ASSEMBLY, Piston and
Cylinder

PISTON PIN LOCK RING
REMOVER/INSTALLER

HD-34623-C

3.21 CYLINDER HEAD, Disassembly

VALVE SPRING COMPRESSOR

HD-34736-B

3.21 CYLINDER HEAD, Assembly

VALVE SPRING COMPRESSOR

HD-34736-B

I

T

OOLS

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

3.21 CYLINDER HEAD, Cleaning and Inspection

VALVE GUIDE CLEANING BRUSH

HD-34751

3.21 CYLINDER HEAD, Replacing Valve Guides

VALVE GUIDE CLEANING BRUSH

HD-34751

3.21 CYLINDER HEAD, Refacing Valve Seats

VALVE GUIDE CLEANING BRUSH

HD-34751

3.23 CRANKCASE, Disassembly

END CAP

HD-34902-7

3.23 CRANKCASE, Fitting Pinion Bearings

END CAP

HD-34902-7

3.23 CRANKCASE, Fitting Pinion Bearings

END CAP

HD-34902-7

3.23 CRANKCASE, Disassembly

BEARING RACE REMOVER AND
INSTALLER KIT

HD-34902-C

3.22 CYLINDER AND PISTON, Connecting Rod Bush-
ings

WRIST PIN BUSHING HONE

HD-35102

5.12 MAIN DRIVE GEAR AND BEARING, Removal

RECEIVER CUP

HD-35316-11

5.12 MAIN DRIVE GEAR AND BEARING, Installation

INSTALLER CUP

HD-35316-12

5.12 MAIN DRIVE GEAR AND BEARING, Removal

BEARING DRIVER

HD-35316-13

5.12 MAIN DRIVE GEAR AND BEARING, Installation

BEARING DRIVER

HD-35316-13

5.12 MAIN DRIVE GEAR AND BEARING, Removal

8 IN. BOLT

HD-35316-4A

5.12 MAIN DRIVE GEAR AND BEARING, Removal

8 IN. BOLT

HD-35316-4A

5.12 MAIN DRIVE GEAR AND BEARING, Installation

8 IN. BOLT

HD-35316-4A

5.12 MAIN DRIVE GEAR AND BEARING, Installation

8 IN. BOLT

HD-35316-4A

5.12 MAIN DRIVE GEAR AND BEARING, Removal

WASHER

HD-35316-7

5.12 MAIN DRIVE GEAR AND BEARING, Installation

WASHER

HD-35316-7

5.12 MAIN DRIVE GEAR AND BEARING, Installation

BEARING DRIVER

HD-35316-8

5.12 MAIN DRIVE GEAR AND BEARING, Removal

BEARING DRIVER

HD-35316-9

5.12 MAIN DRIVE GEAR AND BEARING, Installation

MAIN DRIVE GEAR REMOVER AND
INSTALLER SET

HD-35316-C

5.12 MAIN DRIVE GEAR AND BEARING, Removal

MAIN DRIVE GEAR REMOVER AND
INSTALLER SET

HD-35316-D

1.16 REAR BELT DEFLECTION, Rear Drive Belt:
Sportster Models

BELT TENSION GAUGE

HD-35381A

1.35 TROUBLESHOOTING, Lubrication System

BLACK LIGHT LEAK DETECTOR

HD-35457

3.7 TROUBLESHOOTING, Cylinder Leakage Test

CYLINDER LEAKDOWN TESTER

HD-35667-A

3.21 CYLINDER HEAD, Refacing Valve Seats

NEWAY VALVE SEAT CUTTER SET

HD-35758-C

2.21 FRONT FORK: XL MODELS, Assembly

FORK SEAL AND BUSHING INSTALLA-
TION TOOL

HD-36583

A.14 PACKARD METRI-PACK TERMINALS, Metri-Pack
Terminal Crimps

PACKARD TERMINAL CRIMP TOOL

HD-38125-6

A.8 DEUTSCH MINI TERMINAL REPAIR, Deutsch Mini
Terminal Crimps

PACKARD TERMINAL CRIMPER

HD-38125-7

A.14 PACKARD METRI-PACK TERMINALS, Metri-Pack
Terminal Crimps

PACKARD TERMINAL CRIMPER

HD-38125-7

A.14 PACKARD METRI-PACK TERMINALS, Metri-Pack
Terminal Crimps

PACKARD CRIMPING TOOL

HD-38125-8

A.17 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

PACKARD CRIMPING TOOL

HD-38125-8

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Removal

SPROCKET LOCKING LINK (883 CC)

HD-38362

II TOOLS

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Installation

SPROCKET LOCKING LINK (883 CC)

HD-38362

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Installation

SPROCKET LOCKING LINK (883 CC)

HD-38362

5.6 PRIMARY DRIVE AND CLUTCH: XR
MODELS, Removal

SPROCKET LOCKING LINK

HD-38362

5.6 PRIMARY DRIVE AND CLUTCH: XR
MODELS, Installation

SPROCKET LOCKING LINK

HD-38362

5.5 PRIMARY DRIVE AND CLUTCH: XL MODELS, Dis-
assembly

CLUTCH SPRING FORCING SCREW

HD-38515-91

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Assembly

CLUTCH SPRING FORCING SCREW

HD-38515-91

5.6 PRIMARY DRIVE AND CLUTCH: XR MODELS, Dis-
assembly

CLUTCH SPRING FORCING SCREW

HD-38515-91

5.5 PRIMARY DRIVE AND CLUTCH: XL MODELS, Dis-
assembly

SPRING COMPRESSING TOOL

HD-38515-A

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Assembly

SPRING COMPRESSING TOOL

HD-38515-A

5.6 PRIMARY DRIVE AND CLUTCH: XR MODELS, Dis-
assembly

SPRING COMPRESSING TOOL

HD-38515-A

5.6 PRIMARY DRIVE AND CLUTCH: XR
MODELS, Assembly

SPRING COMPRESSING TOOL

HD-38515-A

3.20 GEARCASE COVER AND CAM GEARS, Bushing
Reaming: XL Only

CAMSHAFT BUSHING REAMER PILOT

HD-38871

2.23 FORK STEM AND BRACKET ASSEMBLY, Cleaning,
Inspection and Repair

STEERING HEAD BEARING RACE
REMOVAL TOOL

HD-39301-A

2.23 FORK STEM AND BRACKET
ASSEMBLY, Assembly and Installation

STEERING HEAD BEARING RACE
INSTALLATION TOOL

HD-39302

6.23 TAIL LAMP: ALL MODELS EXCEPT XL
1200N, Base Replacement

PIN TERMINAL REMOVER

HD-39621-28

3.21 CYLINDER HEAD, Replacing Valve Guides

CYLINDER HEAD SUPPORT STAND

HD-39782-A

3.21 CYLINDER HEAD, Replacing Valve Guides

CYLINDER HEAD HOLDING FIXTURE

HD-39786

3.21 CYLINDER HEAD, Refacing Valve Seats

CYLINDER HEAD HOLDING FIXTURE

HD-39786

3.21 CYLINDER HEAD, Replacing Valve Guides

REAMER T-HANDLE

HD-39847

3.21 CYLINDER HEAD, Replacing Valve Guides

REAMER LUBRICANT

HD-39964

3.22 CYLINDER AND PISTON, Connecting Rod Bush-
ings

REAMER LUBRICANT

HD-39964

A.6 DEUTSCH STANDARD TERMINAL REPAIR, Deutsch
Standard Terminal Crimps

DEUTSCH TERMINAL CRIMP TOOL

HD-39965-A

6.16 IGNITION AND LIGHT SWITCH, Installation

ULTRA TORCH UT-100

HD-39969

6.39 HANDLEBAR SWITCH ASSEMBLIES, Repair Pro-
cedures

ULTRA TORCH UT-100

HD-39969

A.17 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

ULTRA TORCH UT-100

HD-39969

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

FORK TUBE HOLDER

HD-41177

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

FORK TUBE HOLDER

HD-41177

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

FORK TUBE HOLDER

HD-41177

TOOLS III

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

FORK TUBE HOLDER

HD-41177

2.22 FRONT FORK: XR MODELS, Disassembly

FORK TUBE HOLDER

HD-41177

2.22 FRONT FORK: XR MODELS, Disassembly

FORK TUBE HOLDER

HD-41177

2.22 FRONT FORK: XR MODELS, Disassembly

FORK TUBE HOLDER

HD-41177

2.22 FRONT FORK: XR MODELS, Assembly

FORK TUBE HOLDER

HD-41177

2.22 FRONT FORK: XR MODELS, Assembly

FORK TUBE HOLDER

HD-41177

4.19 FUEL PRESSURE TEST, Testing

FUEL PRESSURE GAUGE

HD-41182

6.39 HANDLEBAR SWITCH ASSEMBLIES, Repair Pro-
cedures

HEAT SHIELD ATTACHMENT

HD-41183

A.17 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

HEAT SHIELD ATTACHMENT

HD-41183

4.20 INTAKE LEAK TEST, Leak Tester

PROPANE ENRICHMENT KIT

HD-41417

A.5 DEUTSCH ELECTRICAL CONNECTORS, Deutsch
Connector Repair

DEUTSCH CONNECTOR SERVICE KIT

HD-41475

A.5 DEUTSCH ELECTRICAL CONNECTORS, Deutsch
Connector Repair

FLAT BLADE L-HOOK

HD-41475-100

A.1 AMP MULTILOCK CONNECTORS, AMP Multilock
Connector Repair

AMP MULTILOCK CRIMPER

HD-41609

6.36 OIL PRESSURE SWITCH, Removal

OIL PRESSURE SENDING UNIT WRENCH

HD-41675

5.9 CASE DISASSEMBLY FOR TRANSMISSION
REMOVAL, Engine Removal and Disassembly

ENGINE SUPPORT CRADLE

HD-42310-45

5.16 TRANSMISSION SPROCKET, Removal

ENGINE CRADLE

HD-42310-45

1.6 ENGINE OIL AND FILTER, Changing Oil and Filter

HARLEY-DAVIDSON OIL FILTER WRENCH

HD-42311

3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder
and Piston

PISTON PIN REMOVER

HD-42320-A

3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder
and Piston

PISTON SUPPORT PLATE

HD-42322

3.16 TOP END OVERHAUL: ASSEMBLY, Piston and
Cylinder

PISTON SUPPORT PLATE

HD-42322

5.15 TRANSMISSION INSTALLATION, Assembling
Crankcases

CRANKSHAFT GUIDE TOOL

HD-42326-A

3.18 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

CRANKSHAFT GUIDE TOOL

HD-42326-B

3.18 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

SPROCKET SHAFT BEARING/SEAL
INSTALLATION TOOL

HD-42579-A

3.18 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

CRANKCASE BEARING
REMOVER/INSTALLER BASE

HD-42720-2

A.7 DEUTSCH SOLID BARREL MINI TERMINAL
REPAIR, Deutsch Solid Barrel Terminal Crimps

ELECTRICAL CRIMPER TOOL

HD-42879

3.18 BOTTOM END OVERHAUL: ASSEMBLY, Cam
Gears and Gearcase Cover: XL Models

CRANKSHAFT LOCKING TOOL

HD-43984

2.4 WHEELS, Sealed Wheel Bearings

WHEEL BEARING INSTALLER/REMOVER

HD-44060-B

4.19 FUEL PRESSURE TEST, Testing

FUEL PRESSURE GAUGE ADAPTER

HD-44061

1.6 ENGINE OIL AND FILTER, Changing Oil and Filter

HARLEY-DAVIDSON OIL FILTER WRENCH

HD-44067-A

3.23 CRANKCASE, Disassembly

FLYWHEEL SUPPORT FIXTURE

HD-44358

A.16 PACKARD MICRO-64 CONNECTORS, Packard
Micro-64 Connector Repair

PACKARD MICRO-64 TERMINAL
REMOVER

HD-45928

IV TOOLS

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

6.6 SPEEDOMETER: XL SINGLE GAUGE MODELS
EXCEPT XL 883C/XL 1200C, Installation

CRIMPING TOOL

HD-45929

A.16 PACKARD MICRO-64 CONNECTORS, Packard
Micro-64 Connector Repair

PACKARD MICRO-64 TERMINAL
CRIMPER

HD-45929

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

FRONT FORK COMPRESSOR

HD-45966

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

FRONT FORK COMPRESSOR

HD-45966

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

FRONT FORK COMPRESSOR

HD-45966

2.22 FRONT FORK: XR MODELS, Disassembly

FRONT FORK COMPRESSOR

HD-45966

2.22 FRONT FORK: XR MODELS, Disassembly

FRONT FORK COMPRESSOR

HD-45966

2.22 FRONT FORK: XR MODELS, Assembly

FRONT FORK COMPRESSOR

HD-45966

2.29 REAR ENGINE MOUNT/ISOLATOR, Removal

SHOP DOLLY

HD-45967

3.12 REMOVING ENGINE FROM CHASSIS, Procedure:
XL Models

SHOP DOLLY

HD-45967

3.12 REMOVING ENGINE FROM CHASSIS, Procedure:
XR Models

SHOP DOLLY

HD-45967

3.13 INSTALLING ENGINE IN CHASSIS, Procedure: XL
Models

SHOP DOLLY

HD-45967

3.13 INSTALLING ENGINE IN CHASSIS, Procedure: XR
Models

SHOP DOLLY

HD-45967

2.4 WHEELS, Rear Wheel

FAT JACK

HD-45968

2.28 FRONT ENGINE MOUNT/ISOLATOR, Removal

FAT JACK

HD-45968

2.29 REAR ENGINE MOUNT/ISOLATOR, Installation

FAT JACK

HD-45968

3.12 REMOVING ENGINE FROM CHASSIS, Procedure:
XL Models

FAT JACK

HD-45968

3.12 REMOVING ENGINE FROM CHASSIS, Procedure:
XR Models

FAT JACK

HD-45968

3.13 INSTALLING ENGINE IN CHASSIS, Procedure: XL
Models

FAT JACK

HD-45968

3.13 INSTALLING ENGINE IN CHASSIS, Procedure: XR
Models

FAT JACK

HD-45968

2.25 REAR FORK, Disassembly

BEARING REMOVER/INSTALLER TOOL

HD-46281

5.16 TRANSMISSION SPROCKET, Installation

TRANSMISSION SPROCKET HOLDING
TOOL

HD-46282

5.16 TRANSMISSION SPROCKET, Removal

SPROCKET HOLDING TOOL ADAPTER

HD-46282-1A

5.16 TRANSMISSION SPROCKET, Installation

SPROCKET HOLDING TOOL ADAPTER

HD-46282-1A

5.16 TRANSMISSION SPROCKET, Installation

SPROCKET HOLDING TOOL ADAPTER

HD-46282-1A

5.16 TRANSMISSION SPROCKET, Removal

TRANSMISSION SPROCKET HOLDING
TOOL SET

HD-46282-A

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Removal

SPROCKET LOCKING LINK (1200 CC)

HD-46283

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Installation

PRIMARY DRIVE LOCKING TOOL (1200
CC)

HD-46283

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Installation

PRIMARY DRIVE LOCKING TOOL (1200
CC)

HD-46283

3.12 REMOVING ENGINE FROM CHASSIS, Procedure:
XL Models

ENGINE HOOK

HD-46284

TOOLS V

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

3.12 REMOVING ENGINE FROM CHASSIS, Procedure:
XR Models

ENGINE HOOK

HD-46284

3.13 INSTALLING ENGINE IN CHASSIS, Procedure: XR
Models

ENGINE HOOK

HD-46284

5.15 TRANSMISSION INSTALLATION, Installation

TRANSMISSION ASSEMBLY FIXTURE

HD-46285

3.23 CRANKCASE, Lapping Engine Main Bearing Races

LAPPING TOOL ADAPTER

HD-46287

5.16 TRANSMISSION SPROCKET, Removal

MAINSHAFT LOCK NUT WRENCH

HD-46288

5.16 TRANSMISSION SPROCKET, Installation

MAINSHAFT LOCK NUT WRENCH

HD-46288

3.14 PRECISION COOLING SYSTEM: XR
MODELS, General

OIL LINE REMOVER, 1/2 IN.

HD-46503

3.14 PRECISION COOLING SYSTEM: XR MODELS, Oil
Pump Lines

OIL LINE REMOVER, 1/2 IN.

HD-46503

4.6 FUEL TANK: XL MODELS, Console Replacement

CONSOLE ALIGNMENT RING

HD-47114

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

INNER FORK NUT REMOVER/INSTALLER

HD-47852

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

INNER FORK NUT REMOVER/INSTALLER

HD-47852

2.22 FRONT FORK: XR MODELS, Disassembly

INNER FORK NUT REMOVER/INSTALLER

HD-47852

2.22 FRONT FORK: XR MODELS, Assembly

INNER FORK NUT REMOVER/INSTALLER

HD-47852

5.12 MAIN DRIVE GEAR AND BEARING, Assembly

INNER/OUTER MAIN DRIVE GEAR
NEEDLE BEARING INSTALLATION TOOL:
XL MODELS

HD-47855

5.12 MAIN DRIVE GEAR AND BEARING, Installation

MAIN DRIVE GEAR SEAL INSTALLER KIT

HD-47856

5.12 MAIN DRIVE GEAR AND BEARING, Installation

INSTALLER

HD-47856-1

5.12 MAIN DRIVE GEAR AND BEARING, Installation

PILOT

HD-47856-2

5.12 MAIN DRIVE GEAR AND BEARING, Installation

ADAPTER

HD-47856-4

5.12 MAIN DRIVE GEAR AND BEARING, Installation

LARGE NUT

HD-47856-5

A.9 MOLEX CONNECTORS, Molex Connector Repair

MOLEX ELECTRICAL CONNECTOR TER-
MINAL REMOVER

HD-48114

4.9 ENGINE TEMPERATURE (ET) SENSOR, Removal

TEMPERATURE SENSOR SOCKET

HD-48116-A

A.9 MOLEX CONNECTORS, Crimp Terminal to Lead

ELECTRICAL CRIMP TOOL

HD-48119

4.14 OXYGEN SENSOR, Removal

OXYGEN SENSOR SOCKET

HD-48262

2.22 FRONT FORK: XR MODELS, Removal

TRIPLE TREE WEDGE TOOL

HD-48287

2.22 FRONT FORK: XR MODELS, Installation

TRIPLE TREE WEDGE TOOL

HD-48287

3.4 OIL PRESSURE, Checking Oil Pressure

OIL PRESSURE SENDING UNIT WRENCH

HD-48386

5.12 MAIN DRIVE GEAR AND BEARING, Assembly

INNER/OUTER MAIN DRIVE GEAR
NEEDLE BEARING INSTALLATION TOOL:
XR MODELS

HD-48643

1.20 SHOCK ABSORBER ADJUSTMENT, Shock
Absorber Preload Adjustment: Sportster Models

SPANNER WRENCH

HD-48645

4.14 OXYGEN SENSOR, Removal

OXYGEN SENSOR SOCKET

HD-48647

1.28 IDLE SPEED AND IGNITION TIMING, Idle Speed

DIGITAL TECHNICIAN II

HD-48650

4.19 FUEL PRESSURE TEST, General

DIGITAL TECHNICIAN II

HD-48650

1.16 REAR BELT DEFLECTION, Wheel Alignment

AXLE ALIGNMENT PLUG SET

HD-48856

D.1 COMPENSATING SPROCKET, Sprocket Bearing
Replacement

REAR WHEEL COMPENSATOR
SPROCKET BEARING
REMOVER/INSTALLER

HD-48921

VI TOOLS

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

3.14 PRECISION COOLING SYSTEM: XR
MODELS, General

OIL LINE REMOVER, 3/8 IN.

HD-49096

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

OIL LEVEL GAUGE

HD-59000B

1.22 FRONT FORK OIL, Changing Fork Oil: XR Models

OIL LEVEL GAUGE

HD-59000B

2.22 FRONT FORK: XR MODELS, Assembly

OIL LEVEL GAUGE

HD-59000B

2.22 FRONT FORK: XR MODELS, Assembly

OIL LEVEL GAUGE

HD-59000B

1.22 FRONT FORK OIL, Changing Fork Oil: XL Models

HARLEY-DAVIDSON PRO-LEVEL OIL
GAUGE

HD-59000-B

2.8 TRUING LACED WHEELS, Lateral Truing

SPOKE WRENCH

HD-94681-80

3.22 CYLINDER AND PISTON, Connecting Rod Bush-
ings

CONNECTING ROD BUSHING REAMER

HD-94800-26A

3.20 GEARCASE COVER AND CAM GEARS, Bushing
Reaming: XL Only

REAR INTAKE CAM GEAR BUSHING
REAMER

HD-94803-67

3.21 CYLINDER HEAD, Replacing Rocker Arm Bushings

ROCKER ARM BUSHING REAMER

HD-94804-57

3.20 GEARCASE COVER AND CAM GEARS, Bushing
Reaming: XL Only

PINION SHAFT BUSHING REAMER

HD-94812-1

3.20 GEARCASE COVER AND CAM GEARS, Bushing
Reaming: XL Only

PINION SHAFT BUSHING REAMER

HD-94812-87

1.20 SHOCK ABSORBER ADJUSTMENT, Shock
Absorber Preload Adjustment: Sportster Models

SPANNER WRENCH

HD-94820-75A

3.23 CRANKCASE, Disassembly

CLAW PULLER WEDGE ATTACHMENT

HD-95637-46B

5.12 MAIN DRIVE GEAR AND BEARING, Disassembly

BEARING RACE PULLER

HD-95637-46B

3.20 GEARCASE COVER AND CAM GEARS, Bushing
Inspection and Removal: XL Only

BUSHING AND BEARING PULLER

HD-95760-69A

5.13 TRANSMISSION RIGHT CASE BEAR-
INGS, Removal

BUSHING AND BEARING PULLER

HD-95760-69A

5.13 TRANSMISSION RIGHT CASE BEAR-
INGS, Removal

1/2 IN. COLLET

HD-95765-69A

3.22 CYLINDER AND PISTON, Connecting Rod Bush-
ings

CONNECTING ROD CLAMPING TOOL

HD-95952-33C

3.22 CYLINDER AND PISTON, Connecting Rod Bush-
ings

CONNECTING ROD BUSHING
REMOVER/INSTALLER

HD-95970-32D

3.16 TOP END OVERHAUL: ASSEMBLY, Piston and
Cylinder

PISTON RING COMPRESSOR

HD-96333-51E

3.23 CRANKCASE, Lapping Engine Main Bearing Races

CRANKCASE MAIN BEARING LAPPING
TOOL

HD-96710-40C

3.23 CRANKCASE, Lapping Engine Main Bearing Races

CRANKCASE MAIN BEARING LAP

HD-96718-87

3.21 CYLINDER HEAD, Cleaning and Inspection

VALVE SPRING TESTER

HD-96796-47

3.4 OIL PRESSURE, Checking Oil Pressure

OIL PRESSURE GAUGE ADAPTER

HD-96921-125

3.4 OIL PRESSURE, Checking Oil Pressure

OIL PRESSURE TEST GAUGE KIT

HD-96921-52D

3.4 OIL PRESSURE, Checking Oil Pressure

OIL PRESSURE GAUGE ADAPTER

HD-96925-58

2.8 TRUING LACED WHEELS, Lateral Truing

WHEEL TRUING STAND

HD-99500-80

2.9 CHECKING CAST WHEEL RUNOUT, Radial Runout

WHEEL TRUING AND BALANCING STAND

HD-99500-80

3.23 CRANKCASE, Fitting Pinion Bearings

FORCING SCREW

J-21686-12

3.23 CRANKCASE, Fitting Pinion Bearings

FORCING SCREW

J-21686-12

TOOLS VII

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

3.18 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

TRANSMISSION SHAFT RETAINING RING
PLIERS

J-5586-A

3.23 CRANKCASE, Disassembly

TRANSMISSION SHAFT RETAINING RING
PLIERS

J-5586-A

5.10 TRANSMISSION REMOVAL AND DISAS-
SEMBLY, Mainshaft Disassembly

TRANSMISSION SHAFT RETAINING RING
PLIERS

J-5586-A

3.23 CRANKCASE, Fitting Pinion Bearings

BRIDGE

J-7830-5

3.23 CRANKCASE, Fitting Pinion Bearings

BRIDGE

J-7830-5

4.15 EXHAUST SYSTEM: XL MODELS, General

SNAP-ON WRENCH

PFSX916

5.14 TRANSMISSION LEFT CASE BEARINGS, Removal

SNAP-ON SNAP RING PLIERS

PR-36

3.23 CRANKCASE, Fitting Pinion Bearings

BEARING SEPARATOR

SNAP-ON TOOLS
STOCK NO. CJ950

3.23 CRANKCASE, Fitting Pinion Bearings

BEARING SEPARATOR

SNAP-ON TOOLS
STOCK NO. CJ950

A.13 PACKARD 630 METRI-PACK CONNECTORS, 630
Metri-Pack Connector Repair

SNAP-ON PICK

SNAP-ON TT600-3

VIII TOOLS