Harley Davidson Sportster Models 2009. Service Repair Manual — page 65
28
29
30
27
26
25
24
23
22
21
20
19
17
18
16
15
13
12
14
11
10
9
8
7
5
1
2
3
4
6
sm00278
21.
11.
1.
Damper spring
Diaphragm spring
Spring
2.
22.
12.
Lockplate
Damper spring seat
Retaining ring
13.
3.
23.
Release plate
Nut
Mainshaft nut
24.
14.
4.
Washer
Retaining ring
Outer ramp
5.
25.
15.
Coupling
Clutch hub
Bearing
16.
6.
26.
Adjusting screw
Ball (3)
Inner thrust washer
27.
17.
7.
Needle bearing inner race
Pressure plate
Inner ramp
8.
28.
18.
Retaining ring
Needle bearing
Friction plate, fiber (7)
19.
9.
29.
Steel plate (7)
Retaining ring
Clutch shell and sprocket
30.
20.
10.
Outer thrust washer
Friction plate, narrow, fiber
Spring seat
Figure 5-21. Clutch Assembly: XR Models
2009 Sportster Service: Drive/Transmission 5-21
REMOVAL
TOOL NAME
PART NUMBER
SPROCKET LOCKING LINK
HD-38362
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)
1.
Disconnect negative (-) battery cable from stud on engine
crankcase behind starter motor assembly. See
2.
Open left side cover. See
.
3.
Remove positive (+) battery cable from battery positive
(+) terminal. See
4.
Remove primary cover and discard primary cover gasket.
See
.
NOTES
•
. Make sure not to position the sprocket
locking link (1) too close to the shifter shaft (2). If the
sprocket locking link contacts the shifter shaft while you
are exerting force to loosen the engine sprocket bolt,
damage to the shifter shaft and/or the engine crankcase
may result.
•
The engine sprocket bolt is a single-use fastener and must
be replaced with a new bolt whenever it is removed.
5.
. Install SPROCKET LOCKING LINK (Part
No. HD-38362). Remove and discard the engine sprocket
bolt. Do not remove engine sprocket at this time.
6.
See
. Remove large retaining ring (12).
Remove adjusting screw assembly (13, 14, 15 and 16)
from pressure plate (17).
NOTE
Transmission mainshaft nut (23) has left-hand threads. Turn
nut clockwise to loosen and remove from mainshaft.
7.
Remove nut (23) and spring washer (24). Remove the
clutch assembly, primary chain and engine sprocket from
the vehicle as an assembly.
8.
Inspect primary chain. If damaged or excessively worn,
remove it from engine sprocket and clutch assembly and
replace it with a new one.
9.
Inspect stator and rotor. See
.
Replace damaged parts as necessary.
NOTE
If replacement of primary chain is the only service work
required, proceed directly to
CLUTCH: XR MODELS, Installation
. Skip Step 1 of that pro-
cedure and begin with the NOTE preceding Step 2.
2
1
sm05557
1.
Sprocket locking link
2.
Shifter shaft
Figure 5-22. Loosen Engine Sprocket Bolt
DISASSEMBLY
TOOL NAME
PART NUMBER
CLUTCH SPRING FORCING SCREW
HD-38515-91
SPRING COMPRESSING TOOL
HD-38515-A
1.
See
. With clutch assembly removed from
primary chaincase, install adjusting screw assembly (13,
14, 15 and 16) into pressure plate (17), noting that two
tabs on perimeter of release plate (13) must be inserted
into corresponding recesses in pressure plate. Secure the
adjusting screw assembly with retaining ring (12).
Disassemble clutch using a spring compressing tool. The
diaphragm spring is compressed and, if removed without
proper tools can fly out, which could result in death or
serious injury. (00292a)
2.
.Thread the CLUTCH SPRING FORCING
SCREW (Part No. HD-38515-91) onto the clutch adjusting
screw. Place the bridge of SPRING COMPRESSING
TOOL (Part No. HD-38515-A) against diaphragm spring.
Thread the tool handle onto end of forcing screw.
NOTE
See
. Turn compressing tool handle only enough
to remove retaining ring (9) and spring seat (10). Excessive
compression of diaphragm spring could damage clutch pres-
sure plate.
3.
. With a wrench on the clutch spring for-
cing screw flats to prevent the forcing screw from turning,
turn handle clockwise until tool relieves pressure on
retaining ring (9) and spring seat (10).
4.
Remove and discard retaining ring. Remove spring seat
from the groove in clutch hub prongs. Remove the dia-
phragm spring (11), pressure plate (17), adjusting screw
components (13, 14, 15 and 16) and compressing tool as
an assembly.
5.
Turn the compressing tool handle counterclockwise until
the clutch spring forcing screw disconnects from the clutch
5-22 2009 Sportster Service: Drive/Transmission
adjusting screw. Remove spring seat and diaphragm
spring from pressure plate assembly.
6.
Remove retaining ring (12) and adjusting screw assembly
from pressure plate. If necessary, disassemble adjusting
screw assembly. See
CLUTCH: XR MODELS, Adjusting Screw Disas-
sembly/Assembly
7.
Remove the clutch pack from the clutch hub. The clutch
pack consists of seven friction (fiber) plates (18), seven
steel plates (19), one narrow friction plate (20), one
damper spring (21) and one seat (22).
1
5
3
4
7
6
2
sm05560
1.
Tool handle
2.
Washer
3.
Bearing
4.
Bridge
5.
Forcing screw
6.
Diaphragm spring
7.
Snap ring
Figure 5-23. Compressing Diaphragm Spring: XR Models
CLUTCH PACK CLEANING AND
INSPECTION
1.
Separate the pack into the following components:
a.
Seven fiber plates.
b.
Seven steel plates.
c.
One narrow fiber plate.
d.
One damper spring.
e.
One damper spring seat.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
2.
Wash all parts in cleaning solvent, except fiber (friction)
plates and needle bearing in the clutch hub/shell. Blow
dry with compressed air.
3.
Examine the clutch components as follows:
a.
Check all clutch plates for wear and discoloration.
b.
Inspect each steel (drive) plate for grooves.
c.
Place each steel plate on a flat surface. Using a feeler
gauge, check for flatness in several places. Replace
any plates that are damaged or are warped more than
0.006 in. (0.15 mm).
4.
Inspect the damper spring for cracks or distortion. Install
a new spring if either condition exists.
5.
See
. Check fiber plates for thickness.
a.
Wipe the lubricant from the eight fiber plates (7 regular
and 1 narrow) and stack them on top of each other.
b.
Measure the thickness of the eight stacked fiber plates
with a dial caliper or micrometer. The minimum
thickness must be 0.661 in. (16.789 mm).
c.
If the thickness is less than specified, discard the fiber
plates and steel plates. Install a new set of both fric-
tion and steel plates.
6.
. Inspect primary chain sprocket (1) and
the starter ring gear (2) on the clutch shell. If either
sprocket or ring gear are badly worn or damaged, replace
the clutch shell.
7.
Inspect slots that mate with the clutch plates on both clutch
shell (4) and hub (3). If slots are worn or damaged, replace
shell and/or hub.
sm00283
Figure 5-24. Measuring Friction Plates
2009 Sportster Service: Drive/Transmission 5-23
3
2
1
4
sm00284
1.
Primary chain sprocket
2.
Starter ring gear
3.
Slots on clutch hub
4.
Slots on clutch shell
Figure 5-25. Checking Clutch Shell (Shell Removed from
Primary Shaft)
ADJUSTING SCREW
DISASSEMBLY/ASSEMBLY
1.
. Remove adjusting screw assembly.
a.
Remove large retaining ring.
b.
Remove adjusting screw assembly from pressure
plate.
2.
If necessary, disassemble adjusting screw assembly.
a.
Remove and discard small retaining ring (6).
b.
Separate the adjusting screw (8) from the bearing (7)
and release plate (5).
c.
Remove bearing (7) from release plate (5).
3.
Replace components as required and reassemble
adjusting screw assembly in reverse order.
4.
Install adjusting screw assembly into pressure plate.
a.
See
. Align two tabs on perimeter of
release plate with corresponding recesses (3) in
pressure plate.
b.
Secure the adjusting screw assembly with new
retaining ring.
8
9
7
5
6
1
2
3
4
sm00281
1.
Retaining ring
2.
Spring seat
3.
Diaphragm spring
4.
Retaining ring
5.
Release plate
6.
Retaining ring
7.
Bearing
8.
Adjusting screw
9.
Pressure plate
Figure 5-26. Adjusting Screw Assembly
3
2
1
4
sm00282
1.
Retaining ring
2.
Bearing and release plate
3.
Retaining ring
4.
Adjusting screw
Figure 5-27. Adjusting Screw Assembly
CLUTCH SHELL/HUB INSPECTION
1.
Inspect engine sprocket for damage or excessive wear.
Replace as required.
2.
Disassemble adjusting screw assembly and inspect
bearing, release plate, and adjusting screw. See
5.6 PRIMARY DRIVE AND CLUTCH: XR MODELS,
Adjusting Screw Disassembly/Assembly
.
3.
Remove clutch hub from clutch shell. Inspect primary chain
sprocket and the starter ring gear on the clutch shell.
5-24 2009 Sportster Service: Drive/Transmission
4.
Inspect slots that mate with the clutch plates on both clutch
shell and hub.
5.
See
. Inspect the clutch shell compensating
spring set.
NOTE
It is possible for the compensating springs to float and move
during inspection. This condition is normal.
6.
. Inspect clutch shell needle bearing for
smoothness. Rotate the clutch shell while holding the
clutch hub. If bearing is rough or binds, it must be replaced.
See
5.6 PRIMARY DRIVE AND CLUTCH: XR MODELS,
Clutch Shell Bearing Replacement
.
7.
. Inspect clutch shell bearing inner race
on the back side of the clutch hub for pitting and wear. If
the inner race shows any signs of damage, the complete
hub assembly must be replaced.
8.
Replace damaged parts as necessary.
sm00249
Figure 5-28. Compensating Spring Set
sm00292
Figure 5-29. New Needle Bearing in Clutch Shell
sm00293
Figure 5-30. Clutch Hub Bearing Race
CLUTCH SHELL BEARING REPLACEMENT
TOOL NAME
PART NUMBER
CLUTCH SHELL BEARING
REMOVER/INSTALLER
B-45926
NOTE
The clutch shell uses a caged needle bearing that corresponds
to an inner race installed on the clutch hub.
1.
See
. Place clutch shell on support blocks with
sprocket side facing up.
NOTE
The CLUTCH SHELL BEARING REMOVER/INSTALLER (Part
No. B-45926) is clearly marked for removal and installation
purposes.
2009 Sportster Service: Drive/Transmission 5-25
2.
. Insert removal end of tool into bearing
assembly and remove bearing from clutch shell.
3.
See
. Remove bearing guide from end of
CLUTCH SHELL BEARING REMOVER/INSTALLER (Part
No. B-45926).
4.
Place new needle bearing onto installer end of tool and
insert the bearing guide to prevent the bearing from falling
off during installation and to align bearing with clutch shell.
5.
See
. Place clutch shell on support blocks with
sprocket side facing up.
6.
Press bearing into clutch shell until tool bottoms on the
shell. This will be the correct installed height.
3
1
2
sm00294
1.
Removal end of bearing tool
2.
Installation end of bearing tool
3.
Bearing guide, installer
Figure 5-31. Clutch Shell Bearing Remover/Installer
sm00295
Figure 5-32. Removing Clutch Shell Needle Bearing
2
1
sm00296
1.
Place needle bearing on tool in this location
2.
Bearing guide
Figure 5-33. Bearing Installer
1
sm00297
1.
Needle bearing
Figure 5-34. Installing Clutch Shell Needle Bearing
ASSEMBLY
TOOL NAME
PART NUMBER
SPRING COMPRESSING TOOL
HD-38515-A
1.
Submerge and soak all friction and steel plates in
GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMIS-
SION AND PRIMARY CHAINCASE LUBRICANT for at
least five minutes.
2.
. Install narrow friction plate on the clutch
hub, engaging tabs on plate with slots in clutch shell.
3.
See
. Install damper spring seat (5) on clutch
hub so that it seats inboard of narrow friction plate (4).
4.
Install damper spring (1) on clutch hub with the concave
side up (facing opposite damper spring seat).
5-26 2009 Sportster Service: Drive/Transmission
5.
Install a steel plate and then a friction plate on the clutch
hub. Install six remaining sets in the same manner,
alternating between steel plates and friction plates.
1
2
sm00285
1.
Narrow plate
2.
Regular plate
Figure 5-35. Friction Plates
6.
Place pressure plate, diaphragm spring, adjusting screw
assembly with new retaining ring and spring seat onto
clutch pack.
7.
Compress diaphragm spring and install retaining ring:
a.
See
. Align square openings of pressure
plate and diaphragm spring so that the assembly can
be installed over prongs on clutch hub.
b.
Position spring seat with its larger outer diameter side
toward diaphragm spring.
NOTE
. Turn compressing tool handle only the
amount required to install spring seat and snap ring.
Excessive compression of diaphragm spring could damage
clutch pressure plate.
c.
See
. Install SPRING COMPRESSING
TOOL (Part No. HD-38515-A) onto clutch hub against
diaphragm spring.
d.
Place a wrench on the clutch spring forcing screw
flats to prevent the forcing screw from turning.
e.
Turn compressing tool handle clockwise until dia-
phragm spring compresses just enough to install new
retaining ring into the groove in clutch hub prongs.
f.
With retaining ring fully seated in groove of clutch
hub, carefully loosen and remove compression tool.
NOTE
When the compressing tool is removed, the diaphragm spring
will move outward forcing the spring seat up into the inside of
the retaining ring. The spring seat provides an operating surface
for the diaphragm spring at the same time preventing the
retaining ring from coming out during operation.
1
4
6
2
5
3
sm00286
1.
Damper spring
2.
Clutch hub
3.
Steel plate
4.
Narrow friction plate
5.
Damper spring seat
6.
Clutch shell
Figure 5-36. Clutch Pack Stack-Up (Cut-Away View)
5
4
2
1
3
sm00287
1.
Diaphragm spring (pressure plate below)
2.
Prongs on clutch hub
3.
Retaining ring
4.
Adjusting screw assembly
5.
Spring seat
Figure 5-37. Spring Seat Installation
2009 Sportster Service: Drive/Transmission 5-27
1
5
3
4
7
6
2
sm05560
1.
Tool handle
2.
Washer
3.
Bearing
4.
Bridge
5.
Forcing screw
6.
Diaphragm spring
7.
Snap ring
Figure 5-38. Compressing Diaphragm Spring: XR Models
INSTALLATION
TOOL NAME
PART NUMBER
SPROCKET LOCKING LINK
HD-38362
1.
See
. Remove retaining ring (12). Remove
adjusting screw assembly (13, 14, 15, 16) from pressure
plate (17) to allow installation of the transmission mainshaft
nut and washer.
NOTE
Prior to installing engine sprocket bolt and transmission main-
shaft nut, thoroughly clean threads of engine sprocket shaft,
transmission mainshaft and mainshaft nut to remove any oil
that might contaminate and interfere with locking agent.
2.
Thoroughly clean threads of engine sprocket shaft, trans-
mission mainshaft and mainshaft nut to remove any oil.
NOTE
. Make sure not to position the sprocket locking
link (1) too close to the shifter shaft (2). If the sprocket locking
link contacts the shifter shaft while you are exerting force to
tighten the engine sprocket bolt, damage to the shifter shaft
and/or the engine crankcase may result.
3.
. Install SPROCKET LOCKING LINK (Part
No. HD-38362) (1).
4.
Install new engine sprocket bolt. Tighten to 155-165 ft-lbs
(210.0-224.0 Nm).
NOTE
. Washer (2) must be installed with the word
"out" facing the transmission mainshaft nut (1). Incorrect
assembly can result in clutch and/or transmission failure.
5.
See
. Apply two or three drops of LOCTITE
Threadlocker 262 (red) onto threads on end of transmis-
sion mainshaft. Install spring washer (2) and mainshaft
nut (1) (left-hand threads) on transmission mainshaft.
Tighten nut to 70-80 ft-lbs (95.0-108.6 Nm).
6.
Remove SPROCKET LOCKING LINK.
7.
See
. Install adjusting screw assembly in
pressure plate, noting that two tabs on perimeter of release
plate must be inserted into corresponding recesses in
pressure plate. Secure assembly with a new retaining
ring.
8.
Install primary cover using new gasket. See
9.
Adjust primary chain and clutch. See
10. Fill transmission with GENUINE HARLEY-DAVIDSON
FORMULA+ TRANSMISSION AND PRIMARY CHAIN-
CASE LUBRICANT. See
.
11. Connect battery. See
2
1
sm01266
1.
Sprocket locking link
2.
Shifter shaft
Figure 5-39. Tighten Engine Sprocket Fastener (typical)
1
3
2
sm00290
1.
Mainshaft nut
2.
Washer
3.
Clutch hub
Figure 5-40. Mainshaft Nut and Washer
5-28 2009 Sportster Service: Drive/Transmission
3
1
2
sm00288
1.
Adjusting screw assembly
2.
Retaining ring
3.
Tab recesses
Figure 5-41. Clutch Adjusting Screw Assembly and
Retaining Ring
2009 Sportster Service: Drive/Transmission 5-29
5.7
DRIVE BELT
REMOVAL
XL Models
1.
Remove both mufflers and rear exhaust pipe. See
4.15 EXHAUST SYSTEM: XL MODELS
2.
Models equipped with mid-mount foot controls:
Remove right side rider footrest/brake pedal and mounting
bracket assembly. See
XL MODELS EQUIPPED WITH MID-MOUNT CONTROLS
3.
See
. Remove screw (6), washer (5) and
exhaust pipe clamp bracket (4). Remove two screws (2,
3). Remove sprocket cover (1).
4.
. Remove and discard e-clip (1) and loosen
rear axle nut (4). Decrease belt tension by turning the axle
adjuster nut (2) on each side of rear fork an equal number
of turns counterclockwise.
5.
See
. Remove right lower shock absorber
screw (2), washer (3) and lock nut (1).
3
2
6
5
4
1
sm01356
1.
Sprocket cover
2.
Screw
3.
Screw
4.
Exhaust pipe clamp bracket
5.
Washer
6.
Screw
Figure 5-42. Sprocket Cover: XL Models
1
2
3
4
5
6
sm03591
1.
E-clip
2.
Axle adjuster nut (2)
3.
Axle adjuster (2)
4.
Axle nut
5.
Washer
6.
Protective cap (2)
Figure 5-43. Secondary Drive Belt Adjustment (typical; XL
model shown)
5-30 2009 Sportster Service: Drive/Transmission
4
3
2
8
9
10
7
1
5
6
sm01358
1.
Lock nut
2.
Screw
3.
Washer
4.
Belt guard
5.
Screw
6.
Washer
7.
Nut
8.
Debris deflector
9.
Screw with captive washer (3)
10. Rear fork
Figure 5-44. Belt Guard/Debris Deflector: XL Models
6.
Remove nut (7), screw (5) and washer (6) securing front
of belt guard (4) to rear fork (10). Remove belt guard.
7.
Loosen, but do not remove three screws with captive
washers (9) securing debris deflector (8) to rear fork. Slide
debris deflector forward until keyway slots in deflector
clear screw heads. Remove debris deflector.
Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)
8.
Remove belt.
XR Models
1.
Remove exhaust system. See
.
2.
. Remove screws (2, 3, 4). Remove
sprocket cover (1).
3.
. Remove and discard e-clip (1) and loosen
rear axle nut (4). Decrease belt tension by turning the axle
adjuster nut (2) on each side of rear fork an equal number
of turns counterclockwise.
4.
Remove right lower shock absorber screw, washer and
lock nut. See
.
1
2
3
4
sm05328
1.
Sprocket cover
2.
Rear screw and washer
3.
Front screw
4.
Lower screw
Figure 5-45. Sprocket Cover: XR Models
5.
Remove belt guard and debris deflector. See
.
Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)
6.
Remove belt.
INSTALLATION
XL Models
1.
Install belt onto sprockets.
2.
See
. Install belt guard (4). Install screw (5),
washer (6) and nut (7) securing front of belt guard to rear
fork (10). Tighten to 120-180 in-lbs (13.6-20.3 Nm).
3.
Position debris deflector (8) in place on underside of rear
fork (10).
4.
Fit large end of keyway slots in deflector over screw heads
and captive washers (9). Slide deflector rearward to lock
screws in slots. Tighten screws to 36-60 in-lbs (4.1-6.8
Nm).
5.
Install right lower shock absorber screw (2), washer (3)
and lock nut (1). Tighten to 45-50 ft-lbs (61-68 Nm).
6.
See
. Install sprocket cover (1). Secure with
two screws (2, 3). Note that long screw goes in top hole,
2009 Sportster Service: Drive/Transmission 5-31
short screw in bottom hole. Do not tighten screws at this
time.
7.
Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).
8.
Models equipped with mid-mount foot controls: Install
right side rider footrest/brake pedal and mounting bracket
assembly. See
MODELS EQUIPPED WITH MID-MOUNT CONTROLS
9.
Install rear exhaust pipe and both mufflers. See
4.15 EXHAUST SYSTEM: XL MODELS
10. Adjust belt tension and rear wheel alignment. See
.
11. See
. Tighten rear axle nut (4) to 95-105 ft-lbs
(129-142 Nm). Install new e-clip (1).
XR Models
1.
Install belt onto sprockets.
2.
Install belt guard and debris deflector. See
.
3.
Install right lower shock absorber screw, washer and lock
nut. Tighten to 45-50 ft-lbs (61-68 Nm). See
4.
See
. Install sprocket cover (1). Note that
longer screw goes in top hole, short screw in bottom hole.
a.
Tighten screw (2) to 30-33 ft-lbs (40.7-44.7 Nm)
b.
Tighten screws (3, 4) to 80-120 in-lbs (9.0-13.6 Nm).
5.
Install exhaust system. See
.
6.
Adjust belt tension and rear wheel alignment. See
7.
. Tighten rear axle nut (4) to 95-105 ft-lbs
(129-142 Nm). Install new e-clip (1).
5-32 2009 Sportster Service: Drive/Transmission
5
1
4
3
2
sm02440
1.
Forward bend: 5 in. (127 mm) minimum diameter
2.
Reverse bend: 10 in. (254 mm) minimum diameter
3.
Do not twist
4.
Do not crimp, pinch or kink
5.
Do not pry
Figure 5-46. Proper Drive Belt Handling
IDLER PULLEY: XR MODELS ONLY
Removal
1.
. Remove sprocket cover (1).
NOTE
It is not necessary to remove the drive belt completely.
2.
Remove tension from drive belt and slide belt off drive
sprocket (5). See
.
NOTE
If exhaust system interference prevents removal, loosen all
exhaust system mount fasteners and flange nuts. Pull exhaust
system away from engine to allow room to remove idler
assembly.
3.
Remove nuts (3) and washers (4). Remove idler pulley
and bracket assembly from vehicle.
4.
Inspect idler pulley (7) by spinning and checking for
bearing wear. See
.
NOTE
The idler pulley bearings can not be replaced separately.
2009 Sportster Service: Drive/Transmission 5-33
5.
If idler pulley needs replacement, remove fastener (8) and
bushings (2). Discard idler pulley and replace with new
idler pulley (7).
1
8
2
3
4
6
5
7
sm05541
1.
Sprocket cover
2.
Bushing (2)
3.
Flanged nut (2)
4.
Washer (2)
5.
Drive sprocket
6.
Idler pulley bracket
7.
Idler pulley
8.
Fastener
Figure 5-47. Drive Belt Idler: XR Models
Installation
1.
See
. Install new or existing idler pulley (7), if
removed. Tighten fastener (8) to 70-80 ft-lbs (95-109 Nm).
2.
Install idler pulley and bracket assembly. Install washers
(4) and flanged nuts (3), and tighten to 33-35 ft-lbs (45-47
Nm).
3.
Install drive belt and adjust belt tension and wheel align-
ment. See
.
4.
Install sprocket cover. Tighten rear (larger) screw to 30-
33 ft-lbs (40.7-44.8 Nm).Tighten forward and lower
(smaller) screws to 80-120 in-lbs (9.0-13.6 Nm).
5.
If loosened, align and tighten exhaust system components.
See
4.16 EXHAUST SYSTEM: XR MODELS
5-34 2009 Sportster Service: Drive/Transmission
5.8
TRANSMISSION
GENERAL
. The transmission is a five-speed constant-
mesh type housed in an extension of the crankcase. The
transmission permits the rider to vary the ratio of engine speed-
to-rear driving wheel speed in order to meet the varying condi-
tions of operation.
The transmission is foot-operated by the gear shifter lever,
which transmits the force through a gear shifter shaft. The
shifter shaft actuates a pawl and a shifter fork drum. The shifter
fork drum moves shifter forks, which slide a series of shifter
dogs on the mainshaft and countershaft, into and out of mesh
with the other gears.
2009 Sportster Service: Drive/Transmission 5-35
2
3
4
1
5
2
3
4
1
5
2
3
4
1
5
2
3
4
1
5
2
3
4
1
5
2
3
4
1
5
3
{
1
2
N
1
2
4
5
3
4
5
6
7
sm03353
5.
1.
Power flow
Mainshaft
2.
6.
Countershaft
Moves in
7.
3.
Moves out
Countershaft gears
4.
Sliding member
Figure 5-48. Transmission Power Flow
5-36 2009 Sportster Service: Drive/Transmission
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