Harley Davidson Sportster Models 2009. Service Repair Manual — page 58
12. Oil flows through the feed galley in the crankcase to the
tappet blocks and hydraulic lifters. Cross-drilled pas-
sages intersect the main feed galley and carry oil to each
hydraulic lifter. From this cavity, oil is also fed to the piston
jets.
13. Also from the feed galley in the crankcase, oil flows
through a cross drilled passage to the check valve
assembly and to the cylinder heads through flexible lines.
Oil across the cylinder heads and through passages that
surround the exhaust ports. Oil exits each cylinder head
near the exhaust port.
14. Oil exiting the heads flows to the return oil manifold
where it is mixed with the scavenge oil from the scavenge
pump (25) and is pushed back to the tank.
15. Also from the feed galley in the crankcase, oil enters an
intersecting passage in the oil pump body and cam
support. Oil flow is then routed to the outer bearing of
the rear intake camshaft. A cast-in passage allows oil into
a cavity that surrounds the end of the pinion gear shaft.
16. From the same cavity near the end of the pinion shaft, oil
enters the center hole in the oil pump rotor cover which
intersects with a passage that carries oil to the outer
bearings of the front intake camshaft and rear exhaust
camshaft and is used to lubricate the cam bearings.
17. The outer bearing of the front exhaust camshaft is lubric-
ated through a drilled passage that intersects with the
feed galley.
18. Crankcase end of bearings of the cams are fed through
holes in the camshaft.
19. A small amount of oil flows from the feed galley in the right
crankcase through a restricted orifice, which sprays the
oil onto the rear intake cam gear in the gearcase. Oil is
transferred to the teeth of all the cam gears through the
gear meshing action.
20. Oil enters a hole in the end of the pinion gear shaft and
travels to the right flywheel where it is routed through the
flywheel to the crank pin. Oil is forced through the crank
pin to properly lubricate the rod bearing assembly.
21. Oil flows up passages in the push rods to the rocker arm
shafts and bushings.
22. The valve stems are lubricated by oil supplied through
drilled oil holes in the rocker arms.
23. Oil collected in the push rod areas of the cylinder heads
flows down the push rod covers, through drain holes in
the tappet blocks and into the gearcase. After providing
lubrication to the gearcase components the oil settles to
the bottom of the gearcase where the scavenge pump will
collect it.
24. Feed oil to the rocker area is returned to the gearcase
through a passage in the cylinder head, cylinder, and
crankcase.
25. Oil collected in the sump is splash-fed to the pistons, cyl-
inder walls and flywheel components.
26. Oil collected in the sump area returns to the scavenge
pump through an internal passage located in the rear
section of the sump housing. Oil flow to the pump is
accomplished by the scavenging effect of the pump and
by the pressure created by the downward stroke of the
pistons.
27. Oil collected in the gearcase passes through a passage
in the oil pump body and cam support and is also collected
by the scavenge pump.
28. The scavenge pump pushes the collected oil back to the
oil tank.
29. Crankcase vents to oil tank.
3-24 2009 Sportster Service: Engine
1
17
16
1
2
17
13
14
18
13
11
8
4
14
7
5
3
6
16
10
15
9
18
8
13
11
12
14
10
sm04243
Figure 3-12. Lubrication Diagram: XL Models (Red=Feed Oil, Blue=Return Oil)
Figure 3-12.
Figure 3-12.
Lubrication Diagram: XL Models (Red=Feed Oil, Blue=Return
Oil)
Lubrication Diagram: XL Models (Red=Feed Oil, Blue=Return
Oil)
1
1
25
27
25
26
26
3
5
2
3
6
13
13
4
4
4
18
27
27
22
14
14
14
20
12
8
22
11
6
9
7
10
25
19
24
15
15
19
17
16
18
12
28
22
20
21
23
19
sm05338
Figure 3-13. Lubrication Diagram: XR Models (Red=Feed Oil, Blue=Return Oil)
Figure 3-13.
Figure 3-13.
Lubrication Diagram: XR Models (Red=Feed Oil, Blue=Return
Oil)
Lubrication Diagram: XR Models (Red=Feed Oil, Blue=Return
Oil)
3.9
HOW TO USE THIS SECTION
TYPICAL SYMPTOMS
Symptoms indicating a need for engine repair are often mis-
leading, but generally if more than one symptom is present,
possible causes can be narrowed down to make at least a
partial diagnosis. An above normal consumption of oil, for
example, could be caused by several mechanical faults (see
). But when accompanied by a
blue-gray smoke from the exhaust, and when low compression
is present, it indicates the rings need replacing. Low compres-
sion by itself, however, indicates improperly seated valves, not
worn rings.
Certain knocking noises may be caused by loose bearings,
others by piston slap, a condition where piston or cylinder or
both out of tolerance, allowing the piston to slap from front to
rear of the cylinder as it moves up and down.
Most frequently, valves, rings, pins, bushings, and bearings
need attention at about the same time. If the symptoms can
be narrowed down through the process of elimination to indicate
that any one of the above components is worn, it is best to give
attention to all of the cylinder head and cylinder parts.
TOP END REPAIR
NOTE
During top end disassembly, the engine may be left in the
chassis for service.
If servicing only cylinder head components, pistons, cylinders
and/or upper rod bushings, see
. Two
options are available depending upon engine status.
•
3.10 TOP END SERVICE, Engine in Chassis
•
3.10 TOP END SERVICE, Engine Removed from Chassis
BOTTOM END REPAIR
NOTE
Servicing components in the cam compartment requires only
partial disassembly. This can be done with the engine left in
the chassis.
After disassembling as far as the cylinder heads you may find
that bottom end repair is necessary. Bottom end service may
require either partial or complete disassembly of the engine.
•
To service the cam compartment, see
•
To service components in the flywheel compartment, the
engine must be removed and the crankcase halves split.
See
3.11 BOTTOM END SERVICE, Engine Removed
2009 Sportster Service: Engine 3-29
3.10
TOP END SERVICE
ENGINE IN CHASSIS
Table 3-24. Engine in Chassis
COMPONENT REPAIR
PROCEDURES
SERVICE PROCEDURE
Remove parts necessary to gain access to all components above cylinder deck. See
3.15 TOP END OVERHAUL: DISASSEMBLY, Stripping Motorcycle for Top End
Repair
.
Continue with
3.15 TOP END OVERHAUL: DISASSEMBLY
. Remove/repair sub-
assembly components only if necessary.
*Inspect and repair as necessary. See
3.5 CRANKCASE BREATHING SYSTEM:
XL MODELS
.
Remove rocker arm outer covers. Remove crankcase breathers. See
OVERHAUL: DISASSEMBLY, Cylinder Heads
*Inspect and repair as necessary. See
.
Remove cylinder heads. See
3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder
*Inspect and repair as necessary. See
Remove push rods, push rod covers and tappet covers. See
HAUL: DISASSEMBLY, Cylinder Heads
.
*Inspect and repair as necessary. See
Remove cylinders and pistons. See
3.15 TOP END OVERHAUL: DISASSEMBLY,
Inspect upper connecting rod and repair
as necessary. See
PISTON, Connecting Rod Bushings
.
Complete all appropriate steps under
3.16 TOP END OVERHAUL: ASSEMBLY
.
Complete motorcycle assembly. See
3.16 TOP END OVERHAUL: ASSEMBLY,
Assembling Motorcycle After Top End Repair
* When this step is completed during top end service, you may advance to
3.16 TOP END OVERHAUL: ASSEMBLY
. if no other
work is to be done.
3-30 2009 Sportster Service: Engine
ENGINE REMOVED FROM CHASSIS
Table 3-25. Engine Removed from Chassis
COMPONENT REPAIR
PROCEDURES
SERVICE PROCEDURE
Remove engine from chassis. See
3.12 REMOVING ENGINE FROM CHASSIS
.
Start
3.15 TOP END OVERHAUL: DISASSEMBLY
. Remove and repair subassembly
components as necessary.
*Inspect and repair as necessary. See
3.5 CRANKCASE BREATHING SYSTEM:
XL MODELS
.
Remove rocker arm outer covers. Remove crankcase breathers. See
OVERHAUL: DISASSEMBLY, Cylinder Heads
*Inspect and repair as necessary. See
.
Remove cylinder heads. See
3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder
*Inspect and repair as necessary. See
Remove push rods, push rod covers and tappet covers. See
HAUL: DISASSEMBLY, Cylinder Heads
.
*Inspect and repair as necessary. See
Remove cylinders and pistons. See
3.15 TOP END OVERHAUL: DISASSEMBLY,
Inspect upper connecting rod and repair
as necessary. See
PISTON, Connecting Rod Bushings
.
Complete all appropriate steps under
3.16 TOP END OVERHAUL: ASSEMBLY
.
Install engine in motorcycle. Complete all appropriate steps under
Complete motorcycle assembly. See
3.16 TOP END OVERHAUL: ASSEMBLY,
Assembling Motorcycle After Top End Repair
* When this step is completed during top end service, you may advance to
3.16 TOP END OVERHAUL: ASSEMBLY
. if no other
work is to be done.
2009 Sportster Service: Engine 3-31
3.11
BOTTOM END SERVICE
ENGINE IN CHASSIS
Table 3-26. Engine in Chassis: Cam Compartment Service
COMPONENT REPAIR
PROCEDURES
SERVICE PROCEDURE
Remove parts necessary to gain access to all components above cylinder deck. See
3.15 TOP END OVERHAUL: DISASSEMBLY, Stripping Motorcycle for Top End
Repair
.
Continue with
3.15 TOP END OVERHAUL: DISASSEMBLY
. Remove/repair sub-
assembly components only if necessary.
Inspect and repair as necessary. See
3.5 CRANKCASE BREATHING SYSTEM:
XL MODELS
.
Remove rocker arm outer covers. Remove crankcase breathers. See
OVERHAUL: DISASSEMBLY, Cylinder Heads
Inspect and repair as necessary. See
Remove push rods, push rod covers and tappet covers. See
HAUL: DISASSEMBLY, Cylinder Heads
. Remove tappets. See
OVERHAUL: DISASSEMBLY, Tappets
Continue with
3.17 BOTTOM END OVERHAUL: DISASSEMBLY
*Inspect and repair as necessary. See
3.20 GEARCASE COVER AND CAM
GEARS
Remove gear case cover and cam gears. See
Inspect and repair as necessary. See
.
Remove oil pump components. See
.
Complete all appropriate steps under
3.18 BOTTOM END OVERHAUL: ASSEMBLY
Complete motorcycle assembly. See
3.16 TOP END OVERHAUL: ASSEMBLY,
Assembling Motorcycle After Top End Repair
* When this step is completed during bottom end service, you may advance to
3.18 BOTTOM END OVERHAUL: ASSEMBLY
if no other work is to be done.
3-32 2009 Sportster Service: Engine
ENGINE REMOVED FROM CHASSIS
Table 3-27. Engine Removed from Chassis: Flywheel Compartment Service or Complete Engine Overhaul
COMPONENT REPAIR
PROCEDURES
SERVICE PROCEDURE
Remove engine from chassis. See
3.12 REMOVING ENGINE FROM CHASSIS
.
Start
3.15 TOP END OVERHAUL: DISASSEMBLY
. Remove and repair subassembly
components as necessary.
Inspect and repair as necessary. See
3.5 CRANKCASE BREATHING SYSTEM:
XL MODELS
.
Remove rocker arm outer covers. Remove crankcase breathers. See
OVERHAUL: DISASSEMBLY, Cylinder Heads
Inspect and repair as necessary. See
.
Remove cylinder heads. See
3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder
Inspect and repair as necessary. See
Remove push rods, push rod covers and tappet covers. See
HAUL: DISASSEMBLY, Cylinder Heads
. Remove tappets. See
OVERHAUL: DISASSEMBLY, Tappets
Inspect and repair as necessary. See
Remove cylinders and pistons. See
3.15 TOP END OVERHAUL: DISASSEMBLY,
Inspect upper connecting rod and repair
as necessary. See
PISTON, Connecting Rod Bushings
.
Continue with
3.17 BOTTOM END OVERHAUL: DISASSEMBLY
. Remove and repair
subassembly components as necessary.
Inspect and repair as necessary. See
3.20 GEARCASE COVER AND CAM
GEARS
Remove gearcase cover and cam gears. See
Inspect and repair as necessary. See
.
Remove oil pump. See
Inspect and repair as necessary. See
Complete all appropriate steps under
3.17 BOTTOM END OVERHAUL: DISAS-
to split crankcases and remove flywheel assembly, piston jets,
etc.
Inspect and repair transmission assembly
as necessary. See
,
5.15 TRANSMISSION INSTALLATION
and related subjects.
Complete all appropriate steps under
3.18 BOTTOM END OVERHAUL: ASSEMBLY
Complete all appropriate steps under
3.16 TOP END OVERHAUL: ASSEMBLY
.
Install engine in motorcycle. Complete all appropriate steps under
Complete motorcycle assembly. See
3.16 TOP END OVERHAUL: ASSEMBLY,
Assembling Motorcycle After Top End Repair
2009 Sportster Service: Engine 3-33
3.12
REMOVING ENGINE FROM CHASSIS
GENERAL
If it becomes necessary to remove the engine from the motor-
cycle, follow the step-by-step procedure below. It is important
to follow the procedure as outlined, particularly in the areas of
stabilizer link and engine mount disassembly.
PROCEDURE: XL MODELS
TOOL NAME
PART NUMBER
SHOP DOLLY
HD-45967
FAT JACK
HD-45968
ENGINE HOOK
HD-46284
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
1
3
2
4
sm01471
1.
Cylinder head bracket
2.
Washer (2)
3.
Screw (2)
4.
Horn assembly
Figure 3-14. Horn and Cylinder Head Bracket (Models With
Side Mounted Horn Only)
1.
Position vehicle upright. Purge the fuel supply hose of high
pressure gasoline. Disconnect fuel supply hose from fuel
pump module. See
.
2.
Remove seat.
3.
Remove left side cover. See
Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)
4.
Disconnect negative (-) battery cable from ground stud on
crankcase. Disconnect positive (+) battery cables at bat-
tery. See
5.
Drain primary chaincase/transmission fluid. See
.
6.
Drain oil tank. See
. Do not
install drain plug back in end of drain hose at this time.
7.
Unplug O2 sensor connectors [137], [138] and remove
exhaust pipes and mufflers. See
.
8.
Remove right front footrest assembly and rear brake
linkage.
a.
Models equipped with mid-mount foot controls:
see
2.40 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS
.
b.
Models equipped with forward foot controls: see
2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS
.
9.
Remove screw, washer and exhaust pipe clamp bracket
from sprocket cover. Remove two screws securing
sprocket cover to engine case. Remove sprocket cover.
10. Loosen rear axle nut and move rear axle all the way for-
ward. Tighten axle nut enough to hold the axle and wheel
in position in the rear fork. Remove rear drive belt from
transmission sprocket. See
11. Remove transmission sprocket. See
12. Remove exhaust system interconnect. See
.
13. Disconnect oil tank feed, drain and return hoses from oil
tank. See
. Pull drain hose up through drain
hose sleeve in rear of engine crankcase and remove hose
from vehicle.
14. Drain and remove fuel tank. See
15. Models with side mounted horn: unplug wiring harness
connectors from horn. See
. Remove two
screws (3) and washers (2). Remove cylinder head bracket
(1) with horn (4) from cylinder heads as a unit.
16. Models with front mounted horn: unplug horn con-
nectors and remove horn from horn bracket. See
17. Remove air cleaner cover, air filter and air cleaner backing
plate. See
. California
models: remove EVAP purge hose from induction module.
3-34 2009 Sportster Service: Engine
See
4.21 EVAPORATIVE EMISSIONS CONTROL (CA
.
18. See
4.10 INDUCTION MODULE: XL MODELS
the following connectors from the induction module:
a.
Fuel injector connectors [84], [85].
b.
Temperature/Manifold absolute pressure (TMAP)
sensor connector [80].
c.
Idle Air Control (IAC) connector [87].
d.
Throttle Position (TP) sensor connector [88].
19. Unplug the following electrical connectors from the engine:
a.
Ground wire at powertrain ground stud on crankcase.
b.
Spark plug wires.
c.
Oil pressure switch connector [120]. See
d.
Crank position (CKP) sensor connector [79]. See
6.28 CRANK POSITION SENSOR (CKP)
.
e.
Alternator AC connector [46]. See
.
f.
Neutral indicator switch connector [136]. See
.
g.
Vehicle speed sensor (VSS) connector [65]. See
6.30 VEHICLE SPEED SENSOR (VSS)
h.
Starter relay wire (GN) at starter motor. See
i.
Engine Temperature (ET) sensor connector [90]. Cut
and remove barbed cable strap securing sensor har-
ness to H-bracket. See
20. Disconnect clutch cable and remove from clutch lever on
left handlebar. See
. Remove
cable clips securing clutch cable to frame left front down-
tube.
21. Remove push-in fastener securing right wire harness
caddy to coil bracket. Discard push-in fastener. Remove
screw securing ignition switch to coil bracket. Unplug spark
plug wires from coil. Unplug ignition coil harness connector
[83] from coil. Remove coil and bracket from frame. See
22. Remove screw securing left wire harness caddy to right
wire harness caddy. Separate caddies. See
TRICAL CADDIES, Wire Harness Caddy: XL Models
.
23. Unplug the following harness connectors located in the
wire harness caddies:
a.
Instruments connector [20].
b.
Headlamp connector [38].
c.
Right hand control connector (black) [22].
d.
Left hand control connector (gray) [24].
e.
Front turn signal connector [31].
24. Slide left wire harness caddy between frame and engine,
toward right side of vehicle. Move wire harness caddies
and wiring harnesses out of the way.
25. Remove induction module and intake manifold as a unit.
4.10 INDUCTION MODULE: XL MODELS
. Secure
induction module/intake manifold assembly and throttle
cables out of the way.
26. California models: remove EVAP canister and disconnect
hoses. See
4.21 EVAPORATIVE EMISSIONS CONTROL
.
27. See
. Remove screws (3, 4), grounding strap
(2), stabilizer link (1) and spacer (5).
5
4
3
2
1
sm03428
1.
Stabilizer link
2.
Grounding strap
3.
Screw
4.
Screw
5.
Spacer
Figure 3-15. Rear Stabilizer Link Assembly: Typical (XL
Model Shown)
28. See
. Remove upper stabilizer link (2) and
upper frame bracket (3):
a.
Remove screw (4) securing stabilizer link to engine
bracket (1).
b.
Remove screws (5) and washers (8). Remove horn
bracket (9) (models with front mounted horn) and
upper stabilizer link bracket with stabilizer link.
29. See
. Remove lower stabilizer link (1) and
lower frame bracket (2):
a.
Remove screw (3) securing stabilizer link to engine
crankcase boss.
b.
Remove screws (4), washers (5) and lower frame
bracket with stabilizer link.
2009 Sportster Service: Engine 3-35
30. Remove rider left footrest and mounting bracket assembly
and shift lever.
a.
Models equipped with mid-mount foot controls:
see
2.40 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS
b.
Models equipped with forward foot controls: see
2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS
4
7
9
5
8
6
1
2
3
4
sm03439
1.
Engine bracket
2.
Upper stabilizer link
3.
Upper frame bracket
4.
Screw
5.
Screw (2)
6.
Screw (2)
7.
Lock washer (2)
8.
Washer (2)
9.
Horn bracket (models with front mounted horn)
Figure 3-16. Upper Front Stabilizer Link Assembly:Typical
(XL Model Shown)
4
5
2
1
3
sm03440
1.
Lower stabilizer link
2.
Lower frame bracket
3.
Screw (2)
4.
Screw (2)
5.
Washer (2)
Figure 3-17. Lower Front Stabilizer Link Assembly:Typical
(XL Model Shown)
31. Models equipped with passenger foot rests: remove
left passenger footrest and mounting bracket assembly.
See
NOTE
When removing rear brake master cylinder reservoir and
securing it out of the way in the next step, make sure to keep
the reservoir upright. If the reservoir is allowed to hang upside
down, air bubbles could be introduced into the rear master
cylinder via the feed hose. If this happens, the rear brake must
be bled to remove all air from the hydraulic brake system. See
1.8 BLEEDING HYDRAULIC BRAKE SYSTEM
32. Remove rear brake master cylinder remote reservoir. Do
not disconnect hose from reservoir. See
BRAKE MASTER CYLINDER RESERVOIR
. Secure
reservoir upright, out of the way.
33. Remove rear stop lamp switch from battery tray. Unplug
rear stop lamp switch connectors [121].
Remove screw and p-clamp securing rear brake hose to
battery tray.
Carefully pull rear stop lamp switch and brake lines out of
the way. Be careful not to bend or kink metal brake lines.
See
3-36 2009 Sportster Service: Engine
1
1
2
3
7
6
5
4
8
8
9
10
11
12
14
13
7
sm04963
11.
6.
1.
Screw (2)
Screw (3)
Bolt (2)
2.
12.
7.
Rear isolator mount
Nut
Rear isolator (2)
8.
3.
13.
Front isolator (2)
Screw (2)
Screw
14.
9.
4.
J-clip (2)
Front isolator mount
Rear fork pivot shaft
5.
10.
Rear pivot lockplate
Front mount bolt
Figure 3-18. Engine Mount/Isolator Components (typical)
34. With the aid of a FAT JACK (Part No. HD-45968), support
motorcycle on SHOP DOLLY (Part No. HD-45967).
35. See
. Remove fasteners (13) and j-clip (14)
from each side of frame.
36. Loosen, but do not remove, two front isolator mounting
bracket screws (11) on left side of engine.
37. Loosen, but do not remove, two rear isolator mounting
bracket screws (3) on left side of engine.
38. Attach ENGINE HOOK (Part No. HD-46284) and engine
hoist. Carefully raise engine enough to relieve pressure
from mounting bolts.
39. Remove front engine mount bolt (10) and nut (12).
40. Remove two screws (11) and front isolator mount (9).
41. Remove two rear engine mount/rear fork pivot bolts (1).
Pull rear fork back until fork pivot bosses clear the frame.
42. Remove oil tank vent hose from oil tank. See
.
43. Remove two screws (3) and rear isolator mounting bracket
(2) from frame.
44. Lift engine as necessary and swing assembly out from
chassis toward the left side. Swing rear of engine out first.
Then remove engine from chassis.
2009 Sportster Service: Engine 3-37
PROCEDURE: XR MODELS
TOOL NAME
PART NUMBER
SHOP DOLLY
HD-45967
FAT JACK
HD-45968
ENGINE HOOK
HD-46284
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
2
3
1
sm04923
1.
Fastener, to induction module
2.
Fastener, to cylinder head (2)
3.
Fastener, wire form
Figure 3-19. Induction Module Cover and Wire Form
1.
Position vehicle upright. Purge the fuel supply hose of high
pressure gasoline. Disconnect fuel supply hose from fuel
pump module. See
.
2.
Remove seat. See
3.
Remove left side cover. See
Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)
4.
Disconnect negative (-) battery cable from ground stud on
crankcase. Disconnect positive (+) battery cables at bat-
tery. Remove battery. See
.
5.
Drain primary chaincase/transmission fluid. See
6.
Drain oil tank. See
. Do not
install drain plug back in end of drain hose at this time.
7.
See
. Remove fasteners (1, 2, 3) and remove
induction module cover. Cut tie strap securing TP sensor
harness to side plate.
8.
Disconnect O2 sensor connectors [137], [138] and remove
exhaust pipes and mufflers as an assembly. See
4.16 EXHAUST SYSTEM: XR MODELS
9.
Remove these parts if present:
a.
California models: remove EVAP canister and dis-
connect hoses. See
b.
All other models: remove siren if equipped. See
.
10. See
. Remove two fasteners (1) retaining
siren/canister mount plate and brake line (2) retainer.
11. Remove three screws securing sprocket cover to engine
case. Remove sprocket cover.
12. Remove belt guard and debris deflector from rear fork.
13. Remove fastener securing right shock absorber to the rear
fork.
14. Loosen rear axle nut and move rear axle all the way for-
ward. Tighten axle nut enough to hold the axle and wheel
in position in the rear fork. Remove rear drive belt. See
15. Remove transmission sprocket only if transmission or
engine are to be disassembled. See
16. Disconnect rear stop lamp switch connectors [121].
17. Remove rear brake line from clamps at the bottom of left
rear fork.
NOTE
When securing rear master cylinder out of the way in the next
step, make sure to keep the reservoir upright. If the reservoir
is allowed to hang upside down, air bubbles could be introduced
into the rear master cylinder. If this happens, the rear brake
must be bled to remove all air from the hydraulic brake system.
18. See
. Remove fasteners (1) and remove rider's
right footrest including master cylinder assembly and rear
brake linkage. Be careful not to bend or kink metal brake
line and remove assembly out left side of motorcycle. Tie
assembly, with master cylinder upright, out of the way.
19. Disconnect oil tank feed, drain and return hoses from oil
tank. See
. Pull drain hose up through drain
hose sleeve in rear of engine crankcase and remove hose
from vehicle.
20. Unplug horn connectors and remove horn from horn
bracket. See
21. Remove fasteners securing air cleaner to fuel tank. Drain
and remove fuel tank. See
22. Remove air cleaner from induction module as an
assembly. See
. California
models: remove EVAP purge hose from induction module.
See
4.21 EVAPORATIVE EMISSIONS CONTROL (CA
.
3-38 2009 Sportster Service: Engine
23. See
4.11 INDUCTION MODULE: XR MODELS
and unplug
the following connectors from the induction module:
a.
Fuel injector connectors [84], [85].
b.
Temperature/Manifold absolute pressure (TMAP)
sensor connector [80].
c.
Idle Air Control (IAC) connector [87].
d.
Throttle Position (TP) sensor connector [88].
24. Unplug the following electrical connectors from the engine:
a.
Ground wire at powertrain ground stud on crankcase.
b.
Spark plug wires.
c.
Oil pressure switch connector [120]. See
d.
Crank position (CKP) sensor connector [79]. See
6.28 CRANK POSITION SENSOR (CKP)
.
e.
Alternator AC connector [46] and DC connector [77].
See
f.
Neutral indicator switch connector [136]. See
.
g.
Vehicle speed sensor (VSS) connector [65]. See
6.30 VEHICLE SPEED SENSOR (VSS)
h.
Starter relay wire (GN) at starter motor. See
i.
Engine Temperature (ET) sensor connector [90]. Cut
and remove barbed cable strap securing sensor har-
ness to H-bracket. See
25. If equipped, disconnect jiffy stand sensor connector [133]
and remove sensor. See
26. Disconnect clutch cable and remove from clutch lever on
left handlebar. See
. Remove
cable from oil cooler mount and clips securing clutch cable
to left front downtube.
27. See
. Remove oil cooler fasteners (1) from
frame mounts (2) and remove oil cooler. It is not necessary
to disconnect the oil hoses attached to the oil cooler. Tie
oil cooler to engine.
28. Remove fastener retaining coil bracket to backbone elec-
trical caddy. Remove screw securing ignition switch to coil
bracket. Unplug spark plug wires from coil. Unplug ignition
coil harness connector [83] from coil. Remove coil and
bracket from frame. Position ignition switch out of the way.
See
29. Remove induction module, leaving cables attached. See
4.11 INDUCTION MODULE: XR MODELS
. Secure
induction module assembly and throttle cables out of the
way.
30. See
. Remove screws (3, 4), grounding strap
(2), stabilizer link (1) and spacer (5).
1
2
sm04977
1.
Fastener, siren/canister mount (2)
2.
Rear brake line
Figure 3-20. Siren/Canister Mount Plate and Brake Line
1
2
sm04976
1.
Fastener, footrest mount (2)
2.
Footrest and master cylinder bracket
Figure 3-21. Right Footrest and Rear Master Cylinder
2009 Sportster Service: Engine 3-39
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст