Harley Davidson Sportster Models 2009. Service Repair Manual — page 9
2009 Sportster Models Service Manual
NOTES
TORQUE VALUE
FASTENER
4.7 FUEL TANK: XR MODELS, Assemble Fuel
Tank
4.5-5.1 Nm
40-45 in-lbs
Filler housing screws
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
61.0-67.8 Nm
45-50 ft-lbs
Footrest bracket fastener
2.42 RIDER FOOT CONTROLS: XR MODELS, Left
Footrest and Shift Lever Assembly
61.0-67.8 Nm
45-50 ft-lbs
Footrest bracket fastener: XR models
2.43 PASSENGER FOOTRESTS, XR Models
61-68 Nm)
45-50 ft-lbs
Footrest bracket screw (XR)
2.42 RIDER FOOT CONTROLS: XR
MODELS, Right Footrest and Rear Brake Pedal
Assembly
27.1-32.5 Nm
20-24 ft-lbs
Footrest clevis fastener: XR models
2.42 RIDER FOOT CONTROLS: XR MODELS, Left
Footrest and Shift Lever Assembly
27.1-32.5 Nm
20-24 ft-lbs
Footrest clevis fastener: XR models
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
61.0-67.8 Nm
45-50 ft-lb
Footrest mount fastener
1.13 CLUTCH, Adjustment
61.0-67.8 Nm
45-50 ft-lb
Footrest mount fastener: XR models
1.14 TRANSMISSION LUBRICANT, Transmission
Lubrication: Sportster Models
61.0-67.8 Nm
45-50 ft-lb
Footrest mount fastener: XR models
2.42 RIDER FOOT CONTROLS: XR
MODELS, Right Footrest and Rear Brake Pedal
Assembly
8.1-12.2 Nm
72-108 in-lbs
Footrest wear peg
2.42 RIDER FOOT CONTROLS: XR MODELS, Left
Footrest and Shift Lever Assembly
8.1-12.2 Nm
72-108 in-lbs
Footrest wear peg
1.22 FRONT FORK OIL, Changing Fork Oil: XR
Models
29-39 Nm
21-29 ft-lbs
Fork cap: XR models
1.22 FRONT FORK OIL, Changing Fork Oil: XR
Models
29-39 Nm
21-29 ft-lbs
Fork cap: XR models
2.22 FRONT FORK: XR MODELS, Assembly
17-22 Nm
150-195 in-lbs
Fork cap: XR models
2.22 FRONT FORK: XR
MODELS, Assembly/Second torque. Tighten to
this torque second.
29-39 Nm
21-29 ft-lbs
Fork cap: XR models
2.22 FRONT FORK: XR MODELS, Assembly
29-39 Nm
21-29 ft-lbs
Fork cap: XR models
1.22 FRONT FORK OIL, Changing Fork Oil: XR
Models
17-22 Nm
150-195 in-lbs
Fork cap to retainer nut: XR models
1.22 FRONT FORK OIL, Changing Fork Oil: XR
Models
17-22 Nm
150-195 in-lbs
Fork cap to retainer nut: XR models
2.22 FRONT FORK: XR MODELS, Assembly
17-22 Nm
150-195 in-lbs
Fork cap to retainer nut: XR models
2.22 FRONT FORK: XR MODELS, Assembly
14.9-24.4 Nm
132-216 in-lbs
Fork cartridge fastener
1.22 FRONT FORK OIL, Changing Fork Oil: XL
Models
29.9-78.7 Nm
22-58 ft-lbs
Fork slider tube cap
1.22 FRONT FORK OIL, Changing Fork Oil: XL
Models
29.9-78.7 Nm
22-58 ft-lbs
Fork slider tube cap
2.21 FRONT FORK: XL MODELS, Assembly
14.9-24.4 Nm
132-216 in-lbs
Fork slider tube fastener
2.23 FORK STEM AND BRACKET
ASSEMBLY, Assembly and Installation
8.1-10.9 Nm
72-96 in-lbs
Fork stem bolt, final
2.23 FORK STEM AND BRACKET
ASSEMBLY, Assembly and Installation
31.2-36.6 Nm
23-27 ft-lbs
Fork stem bolt, initial
1.19 STEERING HEAD BEARINGS, Adjustment
40.7-47.5 Nm
30-35 ft-lbs
Fork stem pinch screw
TORQUE VALUES XV
2009 Sportster Models Service Manual
NOTES
TORQUE VALUE
FASTENER
2.23 FORK STEM AND BRACKET
ASSEMBLY, Assembly and Installation
40.7-47.5 Nm
30-35 ft-lbs
Fork stem pinch screw
2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion
9.0-13.6 Nm
80-120 in-lbs
Forward and lower sprocket cover
screws: XR models
5.7 DRIVE BELT, Installation
9.0-13.6 Nm
80-120 in-lbs
Forward and lower sprocket cover
screws: XR models
3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Return Lines
9.5-12.2 Nm
84-108 in-lbs
Front cylinder oil line retainer nut
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
81.4-95.0 Nm
60-70 ft-lbs
Front engine mount bolt
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
81.4-95.0 Nm
60-70 ft-lbs
Front engine mount bolt
2.33 FRONT FENDER, XL Models
10.9-17.6 Nm
96-156 in-lbs
Front fender (XL) mounting screw
2.33 FRONT FENDER, XR Models
20.4-25.8 Nm
15-19 ft-lbs
Front fender (XR) mounting screw
2.33 FRONT FENDER, XR Models
4.1-6.8 Nm
36-60 in-lbs
Front fender bracket (XR) screw
2.21 FRONT FORK: XL MODELS, Installation
40.7-47.5 Nm
30-35 ft-lbs
Front fork bracket pinch screw
2.22 FRONT FORK: XR MODELS, Installation
40.7-47.5 Nm
30-35 ft-lbs
Front fork bracket pinch screw
1.19 STEERING HEAD BEARINGS, Adjustment
40.7-47.5 Nm
30-35 ft-lbs
Front fork lower bracket pinch screw
1.22 FRONT FORK OIL, Changing Fork Oil: XL
Models
1.5-2.0 Nm
13-17 in-lbs
Front fork oil drain screw
2.21 FRONT FORK: XL MODELS, Installation
29.9-78.7 Nm
22-58 ft-lbs
Front fork slider tube cap
1.10 BRAKE PADS AND DISCS: XR
MODELS, Brake Pad Replacement: Front
1.0-2.0 Nm
9-17 in-lbs
Front master cylinder cover screw
2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation
1.0-2.0 Nm
9-17 in-lbs
Front master cylinder cover screw
1.4 MAINTENANCE SCHEDULE, General
1.0-2.0 Nm
9-17 in-lbs
Front master cylinder reservoir cover
screw
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
61.0-67.8 Nm
45-50 ft-lbs
Front muffler mount-to-frame fastener
4.17 FUEL INJECTORS, Installation
6.8 Nm
60 in-lbs
Fuel hose retaining bracket screw
4.18 FUEL PUMP, Assembly
2.1-4.1 Nm
19-36 in-lbs
Fuel pump/sender harness grounding
screw
4.18 FUEL PUMP, Assembly
2.1-4.1 Nm
19-36 in-lbs
Fuel pump bracket mounting screw
1.4 MAINTENANCE SCHEDULE, General
4.5-5.1 Nm
40-45 in-lbs
Fuel pump module mounting screw
1.29 FUEL SUPPLY FILTER, Installation
4.5-5.1 Nm
40-45 in-lbs
Fuel pump module mounting screw
4.18 FUEL PUMP, Installation
4.5-5.1 Nm
40-45 in-lbs
Fuel pump module mounting screw
4.7 FUEL TANK: XR MODELS, Installing Fuel Tank
2.7-3.4 Nm
24-30 in-lbs
Fuel tank cover fastener
4.7 FUEL TANK: XR MODELS, Installing Fuel Tank
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank front fastener
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
20.4-27.1 Nm
15-20 ft-lbs
Fuel tank mounting screw
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
20.4-27.1 Nm
15-20 ft-lbs
Fuel tank mounting screw
3.16 TOP END OVERHAUL:
ASSEMBLY, Assembling Motorcycle After Top End
Repair
20.4-27.1 Nm
15-20 ft-lbs
Fuel tank mounting screw
4.6 FUEL TANK: XL MODELS, Installing Fuel Tank
20.4-27.1 Nm
15-20 ft-lbs
Fuel tank mounting screw
XVI TORQUE VALUES
1.11
TIRES AND WHEELS
TIRES
Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a Harley-Davidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on
the rim or cause tire failure, which could result in death
or serious injury. (00023a)
Use only Harley-Davidson approved tires. See a Harley-
Davidson dealer. Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)
Use inner tubes on laced (wire spoked) wheels. Using
tubeless tires on laced wheels can cause air leaks, which
could result in death or serious injury. (00025a)
NOTES
•
Inner tubes must not be used in radial tires and radial tires
must not be used on laced (wire spoked) wheels.
•
Tubeless tires are used on all Harley-Davidson cast and
disc wheels.
•
Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.
•
New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the
stack compresses the tires and closes down the beads.
Check tire pressure and tread:
•
As part of the pre-ride inspection.
•
At every scheduled service interval.
1.
Inspect each tire for punctures, cuts and breaks.
2.
Inspect each tire for wear. Replace tires before they reach
the tread wear indicator bars.
NOTE
Missing indicator wear bars represent less than 1/32 in. (0.8
mm) tread pattern depth remaining.
3.
Check for proper front and rear tire pressures when tires
are cold. Compare results against
Table 1-8. Tire Sizes: 2009 Sportster Models
NUMBER
SIZE
MOUNT
MODEL
D209 120/70 ZR 18
18 in.
front
XR 1200
D209 180/55 ZR 17
17 in.
rear
XR 1200
D401F 100/90-19
19 in.
front
XL 883, XL 883R, XL 883L,
XL 1200R, XL 1200L, XL 1200N
D402F MH90-21
21 in.
front
XL 883C, XL 1200C
D401 150/80B16
16 in.
rear
All XL models
2009 vehicles use Dunlop Harley-Davidson tires only.
Table 1-9. Tire Pressures: 2009 Sportster Models
TIRE PRESSURE (COLD)
MODEL
REAR
FRONT
kPa
PSI
kPa
PSI
248
36
206
30
XL models (solo rider)
275
40
206
30
XL models (rider and passenger)
262
38
248
36
XR models (solo rider)
290
42
248
36
XR 1200 (rider and passenger)
1-36 2009 Sportster Service: Maintenance
TIRE REPLACEMENT
Inspection
Harley-Davidson tires are equipped with wear bars that
run horizontally across the tread.When wear bars become
visible and only 1/32 in. (0.8 mm) tread depth remains,
replace tire immediately. Using a worn tire can adversely
affect stability and handling, which could result in death
or serious injury. Use only Harley-Davidson approved
replacement tires. (00090b)
See
. Arrows on tire sidewalls pinpoint location of
wear bar indicators.
Tread wear indicator bars will appear on tire tread surfaces
when 1/32 in. (0.8 mm) or less of tire tread remains. See
. Always replace tires before the tread wear indic-
ator bars appear.
When To Replace Tires
New tires are needed if any of the following conditions exist:
1.
Tread wear indicator bars become visible on the tread
surfaces.
2.
Tire cords or fabric become visible through cracked side-
walls, snags or deep cuts.
3.
A bump, bulge or split in the tire.
4.
Puncture, cut or other damage to the tire that cannot be
repaired.
om00846
Figure 1-40. Tire Sidewall Wear Bar Locator
om00845
Figure 1-41. Wear Bar Appearance (Typical)
WHEEL BEARINGS
1.
Replace when bearings exceed end play service wear
limit of 0.002 in. (0.051 mm).
2.
Inspect any time the wheels are removed.
a.
Inspect the play of the wheel bearings by finger while
they are in the wheel.
b.
Rotate the inner bearing race and check for abnormal
noise.
c.
Make sure bearing rotates smoothly.
3.
Check wheel bearings and axle spacers for wear and
corrosion. Excessive play or roughness indicates worn
bearings. Replace bearings in sets only. See
WHEEL SPOKES
Spokes that are too tight can draw nipples through the rim
or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)
If nipples require more than one full turn to tighten spoke,
remove tire to check that spoke protrusion has not dam-
aged tube. (00526b)
1.
Raise motorcycle wheel off the ground.
NOTE
Perform the entire procedure for each spoke, one at a time.
2009 Sportster Service: Maintenance 1-37
2.
Mark one of the spokes with a reference mark to the rim.
3.
Loosen spoke 1/4 turn.
NOTES
•
Use a spoke torque wrench to tighten spokes.
•
Do not tighten spoke more than 1/4 turn past reference
mark. If more tension is needed, label spoke and check
after completing rest of wheel.
4.
Tighten spoke to reference mark. If torque is less then the
value listed in
, continue to tighten spoke until
it reaches the listed torque.
5.
Once the entire wheel has been checked, repeat pro-
cedure for each labeled spoke.
6.
If more than a few spokes were loose, true the entire wheel
following procedure under
Table 1-10. Spoke Nipple Torque Specification
MINIMUM TORQUE
RIM TYPE
55 in-lbs (6.2 Nm)
All
1-38 2009 Sportster Service: Maintenance
1.12
PRIMARY CHAIN
INSPECTION
See
. Check the primary chain for correct tension
by measuring its vertical free play through the primary chain
inspection cover (1) opening located near the top of the primary
cover (2).
NOTES
•
See
. Refer to
. A properly adjusted
primary chain should have the specified vertical free play
in its upper strand. Be sure the measurement is taken
midway between engine and clutch sprockets with
sprockets rotated to the tightest chain position.
•
Always measure the vertical free play with the sprockets
rotated to several different positions. The tightest meas-
urement observed must be within specifications shown in
.
•
The initial primary chain vertical free play specification
used at the Harley-Davidson assembly plant is 1/4-3/8 in.
(6.35-9.53 mm) with a cold engine. The 1/4 in. (6.35 mm)
minimum is only allowed at the absolute tightest point in
the drive, as measured with precision factory equipment.
If a chain has less than 1/4 in. (6.35 mm) vertical free play
(with a cold engine), adjust free play to the "field" specific-
ation of 3/8-1/2 in. (9.53-12.70 mm). The looser specifica-
tion will avoid overtightening, which might otherwise occur
during adjustment using "non-factory" equipment and
methods.
•
An opening between the primary drive and transmission
compartments allows the same lubricant supply to lubricate
moving parts in both compartments. For complete lubrica-
tion service on the primary chain, see
•
Since the primary chain runs in lubricant, little service will
be required other than checking lubricant level and chain
tension. If, through hard usage, the primary chain does
become worn, it must be replaced. Remove and install
the chain following the procedure under
2
3
4
5
6
1
sm03278
1.
Primary chain inspection cover
2.
Primary cover
3.
Clutch inspection cover
4.
Drain plug
5.
Primary chain adjuster screw
6.
Lock nut
Figure 1-42. Primary Cover: All Models (XL Model Shown)
2
1
om00206
1.
Measurement point between sprockets
2.
Free play measurement
Figure 1-43. Primary Chain Vertical Free Play: Sportster
Models
Table 1-11. Primary Chain Adjustment: Sportster Models
MILLIMETERS
INCHES
FREE PLAY
9.5-12.7
3/8-1/2
COLD engine
6.3-9.5
1/4-3/8
HOT engine
ADJUSTMENT
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2009 Sportster Service: Maintenance 1-39
2009 Sportster Models Service Manual
NOTES
TORQUE VALUE
FASTENER
2.32 HANDLEBARS, Installation
4.0-5.1 Nm
35-45 in-lbs
Handlebar switch housing screw
2.32 HANDLEBARS, Installation
4.0-5.1 Nm
35-45 in-lbs
Handlebar switch housing screw
6.40 RIGHT HANDLEBAR SWITCHES, Installation
4.0-5.1 Nm
35-45 in-lbs
Handlebar switch housing screws
6.41 LEFT HANDLEBAR SWITCHES, Installation
4.0-5.1 Nm
35-45 in-lbs
Handlebar switch housing screws
2.32 HANDLEBARS, Installation
16.3-24.4 Nm
12-18 ft-lbs
Handlebar upper clamp/speedometer
housing screw (XL 883C/XL 1200C)
2.32 HANDLEBARS, Installation
16.3-24.4 Nm
12-18 ft-lbs
Handlebar upper clamp/speedometer
housing screw (XL 883C/XL 1200C)
6.22 INDICATOR LAMP MODULE, Replacement:
All Other Models/all except XL 883C/XL 1200C/XL
1200L/XL 1200N
16.3-24.4 Nm
12-18 in-lbs
Handlebar upper clamp screw
1.31 HEADLAMP ALIGNMENT, Headlamp
Adjustment: Sportster Models
40.7-47.5 Nm
30-35 ft-lbs
Headlamp Allen head capscrew
1.31 HEADLAMP ALIGNMENT, Headlamp
Adjustment: Sportster Models
14-27 Nm
120-240 in-lbs
Headlamp clamp nut
3.24 OIL PUMP: XL MODELS, Installation
6.8-10.2 Nm
60-90 in-lbs
High pressure feed hose fitting (to
crankcase)
3.24 OIL PUMP: XL MODELS, Installation
9.6-11.8 Nm
85-105 in-lbs
High pressure feed hose fitting nut
6.37 HORN, Replacement: Models with Front
Mounted Horn
8.1-12.2 Nm
72-108 in-lbs
Horn, front mounted, mounting screw
6.37 HORN, Replacement: Models with Side
Mounted Horn
6.8-20.4 Nm
60-180 in-lbs
Horn, side mounted, acorn nut
6.37 HORN, Replacement: Models with Side
Mounted Horn
9.0-11.3 Nm
80-100 in-lbs
Horn, side mounted, stud nut
2.4 WHEELS, Front Wheel/Cast front wheel
21.7-32.6 Nm
16-24 ft-lbs
Hub plate mounting screw
4.10 INDUCTION MODULE: XL
MODELS, Assembly
6.8 Nm
60 in-lbs
IAC mounting screw
4.11 INDUCTION MODULE: XR
MODELS, Assembly
6.8 Nm
60 in-lbs
IAC mounting screw
4.12 IDLE AIR CONTROL (IAC), Installation: XL
Models
6.8 Nm
60 in-lbs
IAC mounting screw
4.12 IDLE AIR CONTROL (IAC), Installation: XR
Models
6.8 Nm
60 in-lbs
IAC mounting screw (XR models)
5.7 DRIVE BELT, Idler Pulley: XR Models Only
45-47 Nm
33-35 ft-lbs
Idler pulley bracket flanged nut: XR
models
5.7 DRIVE BELT, Idler Pulley: XR Models Only
95-109 Nm
70-80 ft-lbs
Idler pulley fastener: XR models
6.16 IGNITION AND LIGHT SWITCH, Installation
4.0-5.1 Nm
35-45 in-lbs
Ignition/light switch mounting screw
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
4.0-5.1 Nm
34-45 in-lbs
Ignition switch mounting screw
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
4.0-5.1 Nm
34-45 in-lbs
Ignition switch mounting screw
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
27.1-32.5 Nm
20-24 ft-lbs
Induction module cover-to-cylinder head
fastener
4.11 INDUCTION MODULE: XR
MODELS, Installation
27.1-32.5 Nm
20-24 ft-lbs
Induction module cover-to-cylinder head
fastener
4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models
27.1-32.5 Nm
20-24 ft-lbs
Induction module cover-to-cylinder head
fastener
XVIII TORQUE VALUES
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