Harley Davidson Sportster Models 2009. Service Repair Manual — page 10
2009 Sportster Models Service Manual
NOTES
TORQUE VALUE
FASTENER
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
9.5-12.2 Nm
84-108 in-lbs
Induction module cover-to-induction
module fastener
4.11 INDUCTION MODULE: XR
MODELS, Installation
9.5-12.2 Nm
84-108 in-lbs
Induction module cover-to-induction
module fastener
4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models
9.5-12.2 Nm
84-108 in-lbs
Induction module cover-to-induction
module fastener
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
9.5-12.2 Nm
84-108 in-lbs
Induction module cover-to-wire form
fastener
4.11 INDUCTION MODULE: XR
MODELS, Installation
9.5-12.2 Nm
84-108 in-lbs
Induction module cover-to-wire form
fastener
4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models
9.5-12.2 Nm
84-108 in-lbs
Induction module cover-to-wire form
fastener
4.10 INDUCTION MODULE: XL MODELS, Install-
ation
9.5-12.2 Nm
84-108 in-lbs
Induction module mounting bracket
screw
4.10 INDUCTION MODULE: XL
MODELS, Assembly
4.0 Nm
35 in-lbs
Induction module-to-intake manifold
screw
4.10 INDUCTION MODULE: XL
MODELS, Assembly
6.8 Nm
60 in-lbs
Induction module-to-intake manifold
screw
2.36 REAR FENDER: XR MODELS, Installation
8.1-13.6 Nm
72-120 in-lbs
Inner fender screw: XR models
1.22 FRONT FORK OIL, Changing Fork Oil: XR
Models/Hand tighten. Then tighten to torque.
93-113 Nm
69-83 ft-lbs
Inner fork nut, right: XR models
2.22 FRONT FORK: XR MODELS, Assembly/Hand
tighten. Then tighten to torque.
93-113 Nm
69-83 ft-lbs
Inner fork nut, right: XR models
3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers
24.4-29.8 Nm
18-22 ft-lbs
Inner rocker cover bolt, large
3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers
15.3-17.5 Nm
135-155 in-lbs
Inner rocker cover bolt, small
3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers
15.3-17.5 Nm
135-155 in-lbs
Inner rocker cover screw
4.10 INDUCTION MODULE: XL MODELS, Install-
ation
10.9-13.6 Nm
96-120 in-lbs
Intake manifold mounting screw
4.11 INDUCTION MODULE: XR
MODELS, Installation
10.9-13.6 Nm
96-120 in-lbs
Intake manifold mounting screw
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
40.7-44.7 Nm
30-33 ft-lbs
Interconnect bracket-to-frame fastener
2.28 FRONT ENGINE MOUNT/ISOLATOR, Install-
ation
33.9-47.5 Nm
25-35 ft-lbs
Isolator (front) mounting bracket screw
2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion
33.9-47.5 Nm
25-35 ft-lbs
Isolator (front) mounting bracket screw
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
33.9-47.5 Nm
25-35 ft-lbs
Isolator mount screw, front
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
33.9-47.5 Nm
25-35 ft-lbs
Isolator mount screw, front
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
33.9-47.5 Nm
25-35 ft-lbs
Isolator mount screw, rear
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
33.9-47.5 Nm
25-35 ft-lbs
Isolator mount screw, rear
TORQUE VALUES XIX
2009 Sportster Models Service Manual
NOTES
TORQUE VALUE
FASTENER
6.34 JIFFY STAND SWITCH: INTERNATIONAL
MODELS, Installation
10.9-13.6 Nm
96-120 in-lbs
Jiffy stand switch screw
2.34 REAR FENDER: ALL XL MODELS EXCEPT
XL 1200N, Installation
2.3-2.8 Nm
20-25 in-lbs
License plate bracket mounting screw
6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)
1.2-1.3 Nm
14-16 in-lbs
License plate lamp housing screw
6.33 ELECTRICAL CADDIES, Wire Harness
Caddy: XL Models
4.0-5.1 Nm
35-45 in-lbs
Light switch bracket screw
6.33 ELECTRICAL CADDIES, Wire Harness
Caddy: XR Models
4.0-5.1 Nm
35-45 in-lbs
Light switch bracket screw
6.14 STARTER SOLENOID, Solenoid Contacts
7.3-9.0 Nm
65-80 in-lbs
Long post jam nut
2.23 FORK STEM AND BRACKET
ASSEMBLY, Assembly and Installation
40.7-47.5 Nm
30-35 ft-lbs
Lower fork bracket pinch screw
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
61.0-67.8 Nm
45-50 ft-lbs
Lower front retainer plate fastener
2.32 HANDLEBARS, Installation
40.7-54.3 Nm
30-40 ft-lbs
Lower handlebar clamp bolts
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
40.7-44.7 Nm
30-33 ft-lbs
Lower muffler mount nut
2.17 REAR BRAKE CALIPER: XR
MODELS, Installation
40.7-61.0 Nm
30-45 ft-lbs
Lower shock absorber fastener
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
40.7-61.0 Nm
30-45 ft-lb
Lower shock absorber fastener
5.7 DRIVE BELT, Installation
61-68 Nm
45-50 ft-lbs
Lower shock absorber screw
5.7 DRIVE BELT, Installation
61-68 Nm
45-50 ft-lbs
Lower shock absorber screw
2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation
10.9-16.3 Nm
96-144 in-lbs
Mirror stem lock nut
2.31 CLUTCH CONTROL, Assembly and Installa-
tion
10.9-16.3 Nm
96-144 in-lbs
Mirror stem lock nut
2.43 PASSENGER FOOTRESTS, XR Models
20.4-25.8 Nm
15-19 ft-lbs
Muffler bracket-to-footrest bracket screw
(XR)
4.15 EXHAUST SYSTEM: XL MODELS, Installation
40.7-44.8 Nm
30-33 ft-lbs
Muffler interconnect bracket mounting
screw
5.16 TRANSMISSION SPROCKET, Installation
40.7-44.8 Nm
30-33 ft-lbs
Muffler interconnect bracket mounting
screw
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
16.9-20.3 Nm
120-180 in-lbs
Muffler-to-front muffler mount fastener
4.15 EXHAUST SYSTEM: XL MODELS, Installation
20.4-25.8 Nm
15-19 ft-lbs
Muffler-to-interconnect bracket screw
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
16.9-20.3 Nm
120-180 in-lbs
Muffler-to-muffler bolt
4.15 EXHAUST SYSTEM: XL MODELS, Installation
51.6-58.4 Nm
38-43 ft-lbs
Muffler torca clamp nut
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
16.9-20.3 Nm
120-180 in-lbs
Muffler-to-rear muffler mount fastener
5.15 TRANSMISSION INSTALLATION, Assembling
Crankcases
13.6-20.3 Nm
120-180 in-lbs
Neutral indicator switch
6.31 NEUTRAL INDICATOR SWITCH, Replace-
ment
13.6-20.3 Nm
120-180 in-lbs
Neutral indicator switch
4.15 EXHAUST SYSTEM: XL MODELS, Installation
39.3-59.7 Nm
29-44 ft-lbs
O2 sensor
XX TORQUE VALUES
. The primary chain can be adjusted without
removing the primary cover (2). Proceed as follows:
1.
Unplug main fuse. See
.
2.
Remove two hex socket screws securing primary chain
inspection cover (1).
3.
Rotate sprockets to find tightest point on primary chain.
Do not adjust the primary chain tighter than specified.
Running chain too tight will result in excessive wear.
(00202a)
4.
Loosen lock nut (6). Using a 1/4-inch allen wrench, turn
chain adjuster screw (5) clockwise (inward) to reduce free
play or counterclockwise (outward) to increase free play.
Vertical free play must fall within the limits specified in
.
NOTE
If vertical free play cannot be set within the limits specified in
, then primary chain and/or chain adjuster are worn
beyond adjustment limits. Replace parts as necessary. See
5.
See
. When tension is set correctly, hold chain
adjusting screw with allen wrench and tighten lock nut (6)
to 20-25 ft-lbs (27.1-33.9 Nm).
6.
Install primary chain inspection cover (1) and new gasket.
Tighten hex socket screws to 84-120 in-lbs (9.5-13.6 Nm).
7.
Plug in main fuse. See
.
1-40 2009 Sportster Service: Maintenance
1.13
CLUTCH
ADJUSTMENT
All models feature a primary cover and a quick-release clutch
cable to simplify both clutch service and adjustment. See
. Clutch cable adjuster is located in middle of cable,
adjacent to left frame downtube.
sm01436
Figure 1-44. Clutch Cable Adjuster Location (typical; XL
model shown)
1.
See
. Slide rubber boot (1) off cable adjuster
(2).
2.
Holding cable adjuster with 1/2 inch wrench, loosen jam
nut (3) using a 9/16 inch wrench. Back jam nut away from
cable adjuster. Screw adjuster toward jam nut to introduce
a large amount of free play at hand lever.
3.
XL models equipped with mid-mount foot controls:
remove left side rider footrest and mounting bracket
assembly. See
MODELS EQUIPPED WITH MID-MOUNT CONTROLS
for removal.
XR models: remove left side rider footrest, mounting
bracket assembly, and shift linkage. See
for removal.
4.
. Remove six screws (1) and remove
clutch inspection cover (2). Remove and discard quad ring
(7).
5.
Remove hex lockplate with attached spring (3) from flats
of adjusting screw assembly (8). Turn adjusting screw
counterclockwise until resistance is felt. Back off adjusting
screw 1/4 turn.
6.
Slide hex lockplate with spring onto flats of adjusting
screw. If necessary, turn adjusting screw clockwise slightly
so that lockplate slides onto flats while also fitting within
recess of outer ramp.
1
4
3
2
sm01437
1.
Rubber boot
2.
Cable adjuster
3.
Jam nut
4.
Cable end
Figure 1-45. Clutch Cable Adjuster Mechanism
7.
Install new quad ring. Verify that quad ring is fully seated
in groove of primary cover. Install clutch inspection cover
and secure with six screws. Tighten screws in a crosswise
pattern to 84-108 in-lbs (9.5-12.2 Nm).
8.
. Turn cable adjuster (2) clockwise away
from jam nut (3) until slack is eliminated.
9.
See
. Pull clutch cable ferrule away from clutch
lever bracket to check free play. Turn cable adjuster as
necessary to obtain 1/16-1/8 in. (1.6-3.2 mm) free play
between end of cable ferrule and clutch lever bracket.
10. See
. Hold adjuster (2) with 1/2 inch wrench.
Using 9/16 inch wrench, tighten jam nut (3) against cable
adjuster. Cover cable adjuster mechanism with rubber
boot (1).
11. Secure cable in cable retainers attached to down tube.
12. XL models equipped with mid-mount foot controls:
install left side rider footrest and mounting bracket
assembly. Tighten footrest bracket mounting screws to
45-50 ft-lbs (61-68 Nm). See
TROLS: XL MODELS EQUIPPED WITH MID-MOUNT
CONTROLS
for installation.
XR models: install left side rider footrest, shifter and
mounting bracket assembly, and shift linkage. Tighten
footrest bracket mounting screws to 45-50 ft-lb (61.0-67.8
Nm). Tighten linkage fastener to 10-15 ft-lbs (13.6-20.3
Nm). See
2.42 RIDER FOOT CONTROLS: XR MODELS
for installation.
2009 Sportster Service: Maintenance 1-41
9
8
7
5
4
3
1
2
6
10
sm03279
1.
Screw (6)
2.
Clutch inspection cover
3.
Hex lockplate and spring
4.
Nut
5.
Ramp assembly
6.
Coupling
7.
Quad ring
8.
Clutch adjusting screw assembly
9.
Primary cover
10. Clutch cable
Figure 1-46. Clutch Release Mechanism
1
3
2
4
sm01439
1.
Clutch cable
2.
Cable ferrule
3.
Clutch lever bracket
4.
Adjustment range
Figure 1-47. Clutch Freeplay: Adjust for 1/16-1/8 in. (1.6-3.2
mm) Gap Between Ferrule and Bracket
1-42 2009 Sportster Service: Maintenance
1.14
TRANSMISSION LUBRICANT
TRANSMISSION LUBRICATION:
SPORTSTER MODELS
Refer to
. The transmission should be drained and
refilled with fresh lubricant at proper intervals. For best results,
drain lubricant while hot.
NOTE
When checking the transmission lubricant level, motorcycle
should be standing STRAIGHT UP, not leaning on the jiffy
stand. Keep motorcycle upright for a short period of time to
equalize lubricant level in the transmission compartments.
When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)
Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)
Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incom-
plete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)
Check Lubricant Level
1.
Ride motorcycle until engine is warmed up to normal
operating temperature.
2.
Position motorcycle straight up.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
3.
Remove main fuse. See
4.
XL models equipped with mid-mount foot controls:
remove left side rider footrest and mounting bracket
assembly. See
MODELS EQUIPPED WITH MID-MOUNT CONTROLS
for removal.
XR models: remove left side rider footrest, mounting
bracket assembly, and shift linkage. See
for removal.
5.
. Remove screws with washers from clutch
inspection cover (1). Remove clutch inspection cover from
primary cover.
NOTE
The filler access is the clutch inspection cover.
6.
. Verify that lubricant level is even with
bottom of clutch diaphragm spring.
NOTE
Add only enough of GENUINE Harley-Davidson FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT
(Part No. 98851-05 quart) through clutch inspection cover
opening until the lubricant reaches the bottom of clutch dia-
phragm spring.
7.
Install new quad ring. Verify that quad ring is fully seated
in groove of primary cover. Install clutch inspection cover
and secure with six screws. Tighten screws in a crosswise
pattern to 84-108 in-lbs (9.5-12.2 Nm).
8.
XL models equipped with mid-mount foot controls:
install left side rider footrest and mounting bracket
assembly. Tighten footrest bracket mounting screws to
45-50 ft-lbs (61-68 Nm). See
TROLS: XL MODELS EQUIPPED WITH MID-MOUNT
CONTROLS
for installation.
XR models: install left side rider footrest, shifter and
mounting bracket assembly, and shift linkage. Tighten
footrest bracket mounting screws to 45-50 ft-lb (61.0-67.8
Nm). Tighten linkage fastener to 10-15 ft-lbs (13.6-20.3
Nm). See
2.42 RIDER FOOT CONTROLS: XR MODELS
for installation.
9.
Install main fuse.
10. Start engine. Check for any lubricant leaks.
11. Turn engine off.
3
2
1
om00908a
1.
Clutch inspection cover
2.
Drain plug
3.
Primary chain inspection cover
Figure 1-48. Primary Cover: Sportster Models (XL Model
Shown)
2009 Sportster Service: Maintenance 1-43
2009 Sportster Models Service Manual
NOTES
TORQUE VALUE
FASTENER
1.4 MAINTENANCE SCHEDULE, General
19.0-40.7 Nm
14-30 ft-lbs
Primary chaincase drain plug
1.14 TRANSMISSION LUBRICANT, Transmission
Lubrication: Sportster Models/Apply LOCTITE
THREADLOCKER 565 (white).
19.0-40.7 Nm
14-30 ft-lbs
Primary chaincase drain plug
1.12 PRIMARY CHAIN, Adjustment
9.5-13.6 Nm
84-120 in-lbs
Primary chain inspection cover
1.4 MAINTENANCE SCHEDULE, General
9.5-13.6 Nm
84-120 in-lbs
Primary chain inspection cover screw
1.12 PRIMARY CHAIN, Adjustment
27.1-33.9 Nm
20-25 ft-lbs
Primary chain lock nut
5.3 PRIMARY CHAIN ADJUSTER, Installation
11.3-13.5 Nm
100-120 in-lbs
Primary cover screw
5.3 PRIMARY CHAIN ADJUSTER, Installation
19.0-40.7 Nm
14-30 ft-lbs
Primary drain plug
3.16 TOP END OVERHAUL: ASSEMBLY, Push
Rods, Covers, and Retainers
9.0-12.4 Nm
80-110 in-lbs
Push rod retainer screw
3.14 PRECISION COOLING SYSTEM: XR
MODELS, Oil Pump Lines
12.2-17.6 Nm
108-156 in-lbs
Quick connect fitting
3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Return Lines
12.2-17.6 Nm
108-156 in-lbs
Quick connect fitting, cylinder head
return oil
2.17 REAR BRAKE CALIPER: XR
MODELS, Installation
19.6-24.5 Nm
14-18 ft-lbs
Rear caliper mounting bolt
2.17 REAR BRAKE CALIPER: XR
MODELS, Installation
19.6-24.5 Nm
14-18 ft-lbs
Rear caliper pin bolt
2.35 REAR FENDER AND LICENSE PLATE
BRACKET: XL 1200N, Assembly and Installation
2.3-2.8 Nm
20-25 in-lbs
Rear fender brace screw
6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)
2.3-2.8 Nm
20-25 in-lbs
Rear fender brace screw
2.35 REAR FENDER AND LICENSE PLATE
BRACKET: XL 1200N, Assembly and Installation
14.9-24.4 Nm
132-216 in-lbs
Rear fender support screw
2.25 REAR FORK, Installation
81.4-95.0 Nm
60-70 ft-lbs
Rear fork pivot/engine mount bolt
2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion
81.4-95.0 Nm
60-70 ft-lbs
Rear fork pivot/engine mount bolt
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
81.4-95.0 Nm
60-70 ft-lbs
Rear fork pivot/engine mount bolt
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models
81.4-95.0 Nm
60-70 ft-lbs
Rear fork pivot/engine mount bolt
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
20.3-27.1 Nm
15-20 ft-lbs
Rear muffler mount-to-frame fastener
3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Return Lines
9.5-12.2 Nm
84-108 in-lbs
Rear rigid oil line retainer screw
3.14 PRECISION COOLING SYSTEM: XR
MODELS, Oil Pump Lines
9.5-12.2 Nm
84-108 in-lbs
Rear rigid oil line retainer screw
2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion
40.7-44.7 Nm
30-33 ft-lbs
Rear sprocket cover screw: XR models
5.7 DRIVE BELT, Installation
40.7-44.7 Nm
30-33 ft-lbs
Rear sprocket cover screw: XR models
3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models
8.1-13.6 Nm
72-120 in-lbs
Rear stop light switch bracket screw
6.24 TURN SIGNALS, Rear Housing Replacement
3.4-4.5 Nm
30-40 in-lbs
Rear turn signal housing screws: XR
models
6.24 TURN SIGNALS, Rear Housing Replacement
10.9-17.6 Nm
96-156 in-lbs
Rear turn signal housing-to-stalk
2.35 REAR FENDER AND LICENSE PLATE
BRACKET: XL 1200N, Assembly and Installation
14.9-24.4 Nm
132-216 in-lbs
Rear turn signal stalk nut
XXII TORQUE VALUES
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