Harley Davidson Sportster Models 2009. Service Repair Manual — page 24
13
6
13
16
13
12
9
10
8
11
4
5
3
6
7
15
4
3
2
1
14
sm03338
1.
Front fork lower bracket and stem
2.
Seal, lower
3.
Bearing cone (2)
4.
Bear cup (2)
5.
Seal, upper
6.
Front fork upper bracket
7.
Fork stem pinch screw
8.
Washer
9.
Fork stem bolt
10. Fork stem bolt cap (XL 1200R/L only)
11. Pinch screw, upper (2)
12. Slider tube cap
13. Fork assembly (slider and tube assembly, RH and LH)
14. Pinch screw, lower (2)
15. Steering head (part of frame)
16. XL models: 0.42-0.50 in. (10.7-12.7 mm); XR models: 0.25-0.33 in. (6.35-8.38 mm)
Figure 2-164. Front Fork Assembly: XL Models
2009 Sportster Service: Chassis 2-111
CLEANING, INSPECTION AND REPAIR
1.
Thoroughly clean and inspect all parts. Replace any parts
that are bent or damaged.
2.
See
. Inspect the o-ring (6) for damage, wear
or general deterioration; replace as necessary. Replace
all other removed seals.
3.
Inspect damper tube ring(s) (4). Replace ring(s) if dam-
aged or excessively worn.
4.
Check dust seal (12) where it contacts slider tube (9). Dust
seal should provide continuous contact against slider tube
and should not show excessive wear. Check slider tube
where it is contacted by seal. Tube surface should be
shiny, smooth and free of scoring or abrasions.
5.
Inspect small hole in groove of slider tube lower end. Verify
that hole is unobstructed.
ASSEMBLY
TOOL NAME
PART NUMBER
FORK SEAL AND BUSHING
INSTALLATION TOOL
HD-36583
1.
See
. If lower bushing (10) was removed,
install new lower bushing in groove of slider tube (9).
Expand bushing only enough to fit over tube.
2.
Install damper tube ring(s) (4) into groove(s) of damper
tube (3).
3.
Place rebound spring (8) over damper tube (3). Insert
damper tube into slider tube.
4.
Insert spring (5) into slider tube with the tapered end down.
Push damper tube through opening at bottom of slider
tube using spring. Place sleeve (15) over end of damper
tube.
5.
All except XL 1200L: Install spring washer (21) and spring
collar (20) into slider tube.
6.
Install slider tube assembly into slider (16). Install screw
(18) with washer (17) at bottom of slider. Move slider tube
through its full range of travel within slider several times
to verify proper component alignment. Then, applying
downward force on spring, final tighten screw to 132-216
in-lbs (14.9-24.4 Nm).
7.
Place upper bushing (1), spacer (2) (concave side down-
ward), oil seal (14) (lettering side upward) and FORK SEAL
AND BUSHING INSTALLATION TOOL (Part No. HD-
36583) over slider tube. Install bushing, spacer and seal
into slider bore by tapping components downward with
the installation tool. Install internal circle clip (13) into
groove in top of slider bore.
8.
Install dust seal (12) at top of slider.
9.
All except XL 1200N: Install cover (11).
10. XL 1200N: See
. Slide a fork gaiter (2) down
each slider tube. Peal back lower lip (3) and slip over end
of fork slider (1), fitting lower lip down over groove in upper
end of fork slider. Slide upper end of fork gaiter down as
far as possible.
11. See
. Install drain screw and washer (19) into
lower end of slider.
12. Pour the proper amount of TYPE "E" HYDRAULIC FORK
OIL into top end of slider tube. See
13. Install slider tube cap (7) with o-ring (6). Screw tube cap
all the way into slider tube. Finger-tighten only at this time.
2-112 2009 Sportster Service: Chassis
7
6
20
21
3
5
8
9
10
11
22
12
13
14
2
1
15
16
19
17
18
4
sm03342
12.
1.
Dust seal
Upper bushing
2.
13.
Spacer
Internal circle clip
14.
3.
Oil seal
Damper tube
4.
15.
Damper tube ring
Sleeve
16.
5.
Slider
Spring
6.
17.
O-ring
Washer
18.
7.
Screw
Tube cap
8.
19.
Rebound spring
Drain screw and washer
20.
9.
Spring collar (all except XL 1200L)
Slider tube
10.
21.
Lower bushing
Spring washer (all except XL 1200L)
22.
11.
Fork gaiter (XL 1200N) only)
Cover (all except XL 1200N)
Figure 2-165. Front Slider Tube/Slider Assembly: XL Models
INSTALLATION
1.
See
. Insert each fork assembly (13) through
front fork lower (1) and upper (6) brackets. Position slider
tubes so that top of each tube cap (12) extends 0.42-0.50
in. (10.7-12.7 mm) above top surface of front fork upper
bracket.
2.
Tighten front fork upper and lower bracket pinch screws
(11 and 14) to 30-35 ft-lbs (40.7-47.5 Nm).
2009 Sportster Service: Chassis 2-113
3.
Now tighten slider tube caps to 22-58 ft-lbs (29.9-78.7
Nm).
4.
XL 1200N: See
. Slide upper end of each
fork gaiter (2) up until it contacts underside of front fork
lower bracket (4).
5.
Install front fender. See
. Tighten
fasteners to 96-156 in-lbs (10.9-17.6 Nm).
6.
Install front wheel assembly and front brake caliper. See
1
3
2
4
sm01212
1.
Fork slider (2)
2.
Fork gaiter (2)
3.
Fork gaiter lower lip
4.
Front fork lower bracket
Figure 2-166. Fork Gaiter: XL 1200N Only
2-114 2009 Sportster Service: Chassis
2.22
FRONT FORK: XR MODELS
GENERAL
The front fork consists of two telescoping tube/slider assem-
blies. Each tube/slider assembly has an internal compression
spring, which supports the forward weight of the vehicle/rider
and extends and retracts to cushion the ride over rough or
irregular road surfaces. An oil-filled damping mechanism con-
trols the telescoping action of each tube/slider assembly.
REMOVAL
TOOL NAME
PART NUMBER
TRIPLE TREE WEDGE TOOL
HD-48287
1.
Remove front brake calipers. See
2.
Remove front wheel assembly. See
3.
Remove front fender and bracket assembly. See
4.
See
. Remove upper and lower fork bracket
pinch bolts.
5.
Using TRIPLE TREE WEDGE TOOL (Part No. HD-48287),
insert wedge in fork brackets to relieve clamping pressure
on fork tubes.
6.
Remove fork from upper and lower fork brackets.
7.
Repeat steps for other side.
sm04451
Figure 2-167. Insert Triple Tree Wedge (typical)
DISASSEMBLY
TOOL NAME
PART NUMBER
FORK TUBE HOLDER
HD-41177
FRONT FORK COMPRESSOR
HD-45966
INNER FORK NUT
REMOVER/INSTALLER
HD-47852
Left Side
Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)
NOTES
•
When using FRONT FORK COMPRESSOR be sure not
to bind the outer fork tube on the tool.
•
FRONT FORK COMPRESSOR (Part No. HD-45966)
comes with a cup and screw that are for FLT models only
and not to be used with this fork assembly.
sm03135
Figure 2-168. Clamp Fork and Remove Fork Cap
1.
. Using FORK TUBE HOLDER (Part
No. HD-41177), mount fork assembly in vise.
2.
Remove fork cap.
2009 Sportster Service: Chassis 2-115
sm03136
Figure 2-169. Compress Fork Assembly
3.
See
. Compress fork using FRONT FORK
COMPRESSOR (Part No. HD-45966).
1
2
3
sm03137
1.
Fork cap
2.
Retaining nut
3.
Keeper
Figure 2-170. Remove Keeper
NOTE
Note position of retaining nut with shoulder of nut facing away
from fork cap. Be sure to install in the same manner.
4.
See
. Remove keeper and loosen retaining
nut, and fork cap from cartridge assembly.
5.
Remove Front Fork Compressor.
sm03138
Figure 2-171. Remove Collar, and Spring Assembly
6.
See
. Remove collar and spring from fork
assembly.
7.
Remove fork from vise and drain fork oil into a suitable
container by tipping fork upside down and stroke cartridge
plunger to remove excess fork oil.
2-116 2009 Sportster Service: Chassis
sm03139
Figure 2-172. Remove Fastener and Copper Washer
NOTE
Always use soft jaws for bench vise when placing any fork
components into vise to prevent damage to components.
8.
. Place fork slider into bench vise with
soft-jaws and remove fastener and copper washer from
bottom of fork assembly.
sm03140
Figure 2-173. Cartridge Assembly
9.
Remove fork from vise.
10. See
. Place fork in vise using FORK TUBE
HOLDER (Part No. HD-41177). Remove cartridge
assembly from fork slider.
sm03141
Figure 2-174. Remove Chrome Dust Cover
11. See
. Using a blunt soft object (such as a
wood dowel or chisel with duct tape), gently tap chrome
dust cover away from seat, remove dust seal, lock ring,
fork seal, spacer, and bushing from fork tube. Then,
expand fork tube and slider against each other (in a slider-
hammer effect) repeatedly to free fork slider from fork tube.
Use caution not to damage components.
1
2
3
4
5
sm03142
1.
Bushing
2.
Spacer
3.
Fork seal
4.
Lock ring
5.
Dust seal
Figure 2-175. Seal Components
12. See
. Once fork tube and slider are separated,
remove dust seal, lock ring, fork seal, spacer, bushing and
chrome dust cover (not shown) from fork slider.
Right Side
Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)
2009 Sportster Service: Chassis 2-117
1.
See
. Using FORK TUBE HOLDER (Part
No. HD-41177), mount fork assembly in vise.
sm03143
Figure 2-176. Clamp Fork and Loosen Fork Cap
2.
Loosen fork cap.
1
2
sm05680
1.
Fork cap
2.
Retaining nut
Figure 2-177. Remove/Install Fork Cap and Retaining Nut
3.
. Back retaining nut away from fork cap.
Remove fork cap and retainer nut from inner fork nut
threaded shaft.
NOTE
Do not fully extend fork assembly. Extending fork will cause
oil to leak from bleed hole.
4.
See
. Using INNER FORK NUT
REMOVER/INSTALLER (Part No. HD-47852) and remove
inner fork nut assembly from fork tube.
sm03145
Figure 2-178. Inner Fork Nut
NOTE
Note positioning of collar, washer and spring for assembly.
5.
See
. Remove collar, washer and spring from
fork assembly.
6.
Remove fork from vise and drain fork oil into a suitable
container by tipping fork upside down and drain excess
fork oil into suitable container.
sm03146
Figure 2-179. Remove Collar, Washer and Spring
7.
. Using FORK TUBE HOLDER (Part
No. HD-41177), mount fork assembly in vise.
2-118 2009 Sportster Service: Chassis
sm03141
Figure 2-180. Remove Chrome Dust Cover
8.
Using a blunt soft object (such as a wood dowel, or chisel
with duct tape), gently tap chrome dust cover away from
seat, remove dust seal, lock ring, fork seal, spacer, and
bushing from fork tube. Then, by expanding fork and slider
against each other (in a slider-hammer effect) repeatedly,
pull slider free from fork tube. Use caution not to damage
components.
1
2
3
4
5
sm03142
1.
Bushing
2.
Spacer
3.
Fork seal (chamfered lips must face oil)
4.
Lock ring
5.
Dust seal
Figure 2-181. Seal Components
9.
. Once fork tube and slider are separated,
remove dust seal, lock ring, fork seal, spacer, bushing and
chrome dust cover (not shown) from fork slider.
CLEANING AND INSPECTION
1.
Thoroughly clean and inspect each part. If inspection
shows that any parts are bent or damaged, those parts
should be repaired or replaced.
2.
Inspect fork tube bushing and slider guide bushing and
replace as required.
3.
Always replace oil seals and o-rings.
4.
Check dust cover there it rubs on fork tube. Dust cover
should not show any wear.
5.
If springs are damaged, replace springs.
6.
If a fork tube or slider is bent or damaged, replace it.
7.
Replace all other worn or damaged components as
necessary.
NOTES
•
Any time fork pinch bolts are loosened or removed for any
reason, the following procedure must be performed. Fork
tube installation process is extremely critical and must
follow this procedure with no exceptions. Failure to prop-
erly clean the threads will cause improper torque readings
upon assembly, causing loss of vehicle control, resulting
in death or serious injury.
•
New bolts are recommended for assembly. If the original
bolts are to be reused, completely clean excess lock patch
from pinch bolt threads using a wire wheel. Wash bolts
with solvent and dry thoroughly before installing.
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)
•
Clean bolt holes using a bottoming thread tap and blow
bolt hole threads clean with compressed air.
8.
Thoroughly clean all locking material from the fastener
and bracket bolt hole threads. Fork pinch bolts must be
thoroughly cleaned of all lock patch material. Fork bracket
bolt holes must be tapped with a bottoming tap and blown
clear with compressed air to remove excess lock patch
material. If bolts can not be completely cleaned, it is
required that new fork pinch bolts be installed.
ASSEMBLY
TOOL NAME
PART NUMBER
FORK SEAL DRIVER
B-42571
FRONT FORK TUBE HOLDER
HD-41177
FRONT FORK COMPRESSOR
HD-45966
INNER FORK NUT
REMOVER/INSTALLER
HD-47852
OIL LEVEL GAUGE
HD-59000B
Left Side
NOTE
Chamfered lips on oil seal MUST face towards oil in fork.
1.
See
. Use sleeve from fork seal driver and
install chrome dust cover (not shown) and components
onto fork slider in order shown.
2009 Sportster Service: Chassis 2-119
1
2
3
4
5
sm03142
1.
Bushing
2.
Spacer
3.
Fork seal (chamfered lips must face oil)
4.
Lock ring
5.
Dust seal
Figure 2-182. Fork Tube Shown Installed In Order of
Installation
2.
Lightly coat fork slider and bushing with fork oil and gently
install slider into fork tube.
1
2
sm03148
1.
Fork cartridge
2.
Fork tube
Figure 2-183. Install Fork Cartridge
3.
See
. Using FRONT FORK TUBE
HOLDER (Part No. HD-41177), mount fork assembly in
vise.
4.
Make sure cap (centering plate) is on bottom end of fork
cartridge and install fork cartridge (big end first) into fork
slider.
5.
Remove fork and FRONT FORK TUBE HOLDER from
vise.
sm03139
Figure 2-184. Install Fastener and Copper Washer
NOTE
Always use soft jaws for bench vise when placing any fork
components into vise to prevent damage to components.
6.
See
. Using a vise with soft jaws, clamp fork
slider in vise. Install new fastener and copper washer to
hold fork cartridge in place inside fork tube. Tighten to
132-216 in-lbs (14.9-24.4 Nm).
7.
Remove fork from vise.
8.
Using FRONT FORK TUBE HOLDER (Part No. HD-
41177), mount fork assembly in vise.
9.
See
. Assemble the FORK SEAL
DRIVER (Part No. B-42571) over fork slider in front of oil
seal with the long end of tool facing seal. Install parts in
the following order: bushing, spacer, and drive fork seal
into fork tube bore with tool until tool is flush with fork
slider.
10. Install lock ring into groove in top of oil seal. Verify lock
ring is properly seated.
sm03149
Figure 2-185. Install Bushing, Spacer, and Install Fork Seal
in Place with Seal Driver
11. See
. Remove FORK SEAL DRIVER, reverse
tool to short side of tool to prepare to install chrome dust
cover. Rotate slider cover to match any removal burrs in
slider and tap chrome dust cover into place.
2-120 2009 Sportster Service: Chassis
sm03151
Figure 2-186. Install Chrome Dust Cover
Table 2-25. Oil Level, Left Fork
VOLUME
MEASUREMENT
613 cc
20.7 oz
71 mm
2.8 in.
12. Adjust fork assembly to be vertical in vise and fully com-
pressed.
13. Fill fork with Harley-Davidson TYPE E FORK OIL (Part
No. HD-99884-80) until it is approximately 2.0 in. (50.8
mm) from top of fork tube.
sm03152
Figure 2-187. Pump Cartridge
14. See
. Slowly pump cartridge 8 to 10 times to
exhaust air from assembly.
sm03154
Figure 2-188. Measure Fork Oil
NOTE
Fork oil level is measured from top of fork tube, with spacer
and spring removed and fork fully compressed.
15. See
. Fully compress fork and adjust the oil
level to specification from top of fork tube using OIL LEVEL
GAUGE (Part No. HD-59000B). Refer to
NOTE
Coil windings tighten at bottom of spring. Be sure to install in
this manner.
16. See
. Fully extend fork and install spring in
fork tube (with tightly wound end at bottom), washer and
collar.
1
2
sm03155
1.
Collar
2.
Spring
Figure 2-189. Collar and Spring Assembly
2009 Sportster Service: Chassis 2-121
Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)
17. See
. Compress fork using FRONT FORK
COMPRESSOR (Part No. HD-45966).
18. Install keeper.
sm03156
Figure 2-190. Install Keeper
19. Install retainer nut on cartridge rod 0.551 in. (14 mm) from
top of rod and install fork cap onto cartridge rod.
20. Install fork cap on inner rod and tighten against the retainer
nut to 150-195 in-lbs (17-22 Nm) while holding retainer
nut with wrench.
21. Release tension and remove fork compressing tool.
sm03143
Figure 2-191. Install Fork Cap
22. See
. Install fork cap and tighten to 21-29 ft-
lbs (29-39 Nm).
Right Side
1.
Using FORK TUBE HOLDER (Part No. HD-41177), mount
fork assembly in vise vertically and fully compress fork.
2.
See
. Install chrome dust cover (not shown)
and components onto fork slider in order shown.
1
2
3
4
5
sm03142
1.
Bushing
2.
Spacer
3.
Fork seal (chamfered lips must face oil)
4.
Lock ring
5.
Dust seal
Figure 2-192. Seal Components
3.
Lightly coat fork slider and bushing with fork oil and gently
install slider into fork tube.
sm03149
Figure 2-193. Install Seal Components
NOTE
Chamfered lips on oil seal MUST face towards oil in fork.
4.
See
. Assemble the FORK SEAL
DRIVER (Part No. B-42571) over fork slider in front of oil
seal with the long end of tool facing seal and assemble in
the following order: Install bushing, spacer, and drive fork
seal into fork tube bore with tool until tool is flush with fork
slider.
5.
Install lock ring into groove in top of oil seal. Verify lock
ring is properly seated.
6.
See
. Remove FORK SEAL DRIVER and
reverse tool to short side of tool to prepare to install
chrome dust cover. Rotate slider cover to match any
removal burrs in slider and tap chrome dust cover into
place.
2-122 2009 Sportster Service: Chassis
sm03151
Figure 2-194. Install Chrome Dust Cover
Table 2-26. Oil Level, Right Fork
VOLUME
MEASUREMENT
684 cc
23.1 oz
93 mm
3.7 in.
7.
Using FORK TUBE HOLDER (Part No. HD-41177), mount
fork assembly in vise vertically and fully compress fork.
NOTE
Measure fork oil level from top of fork tube using the OIL LEVEL
GAUGE (Part No. HD-59000B).
8.
Fill fork with Harley-Davidson TYPE E FORK OIL (Part
No. HD-99884-80) to specification shown in
sm03154
Figure 2-195. Measure Fork Oil
9.
Fully extend fork.
1
2
3
sm03157
1.
Spring collar
2.
Washer
3.
Rebound spring
Figure 2-196. Collar, Washer and Spring Assembly
10. See
. Install rebound spring in fork tube (with
tightly wound end at bottom), washer, and spring collar.
11. Verify that washer has properly seated on top of spring.
sm03158
Figure 2-197. Inner Fork Nut
12. See
. Insert inner fork nut and finger tighten.
Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)
2009 Sportster Service: Chassis 2-123
NOTE
To prevent cross threading fork tube damper cups and caps,
use caution when threading in the caps with the spring com-
pressed. It may be helpful to use a palm-ratchet during this
process.
13. See
. Final tighten inner fork nut to 69-83 ft-
lbs (93-113 Nm) using INNER FORK NUT
REMOVER/INSTALLER (Part No. HD-47852).
sm03159
Figure 2-198. Hand Tighten
14. See
. Install retainer nut (retainer nut must
be installed 0.551 in (14 mm) from top of threaded shaft).
1
2
sm05680
1.
Fork cap
2.
Retaining nut
Figure 2-199. Remove/Install Fork Cap and Retaining Nut
15. Install fork cap on inner rod and tighten against the retainer
nut to 150-195 in-lbs (17-22 Nm) while holding retainer
nut with wrench.
16. Apply a light coat of fork oil on o-ring and thread cap into
fork tube. Tighten fork cap to 21-29 ft-lbs (29-39 Nm).
INSTALLATION
TOOL NAME
PART NUMBER
TRIPLE TREE WEDGE TOOL
HD-48287
Any time fork pinch bolts are loosened or removed for any
reason, the bolts and threaded holes must be completely clean
of excess lock patch material. If the threads have not been
properly cleaned, follow procedure in
MODELS, Cleaning and Inspection
. Failure to properly clean
these threads will cause improper torque readings upon
assembly and can result in loss of vehicle control, death or
serious injury.
NOTES
•
It is recommended that new fork pinch bolts be installed.
If new bolts are not readily available, use a wire grinder
wheel to remove all remaining lock patch from original
bolts, wash bolts in clean solvent and dry thoroughly.
•
Fork tube installation height is also critical and must match
the opposite side exactly for proper vehicle operation,
reliability and performance.
•
When installing fork leg in triple trees, do not twist fork leg
to avoid damage to cosmetic finishes.
1.
Identify left and right side fork assemblies.
2.
Insert fork assembly from the lower fork bracket upward
through the upper fork bracket.
3.
Remove TRIPLE TREE WEDGE TOOL (Part No. HD-
48287) used during removal process.
4.
. Measure distance from top of upper
fork bracket to top of fork assembly. Both sides must be
exactly the same and measure 0.250-0.330 in (6.35-8.38
mm).
sm05356
Figure 2-200. Fork Installation Height Measurement
NOTE
If new bolts are not readily available, use a wire grinder wheel
to remove all remaining lock patch from original bolts, wash
bolts in clean solvent and dry thoroughly. Apply two drops of
LOCTITE® 262 to the first 1/4 in. (6.35 mm) of the end threads.
Install screws in triple clamp clamps.
2-124 2009 Sportster Service: Chassis
5.
Install new pinch bolts with lock patch or original bolts
using Loctite.
6.
Verify fork tube installation measurement is 0.250-0.330
in (6.35-8.38 mm).
7.
Tighten pinch bolts to 30-35 ft-lbs (40.7-47.5 Nm).
8.
Install front fender and bracket. See
9.
Install front brake caliper hydraulic lines and install front
brake calipers. See
10. Install front wheel and align the wheel to the forks. See
11. Install negative battery cable. Tighten to 60-70 in-lbs (6.8-
7.9 Nm).
2009 Sportster Service: Chassis 2-125
2.23
FORK STEM AND BRACKET ASSEMBLY
REMOVAL AND DISASSEMBLY
1.
Place a protective cover over fuel tank. Remove the fork
assemblies. See
.
2.
See
. Remove stem bolt cap (10) (XL 1200R
only), fork stem bolt (9) and washer (8). Loosen fork stem
pinch screw (7).
3.
Lift handlebar assembly from steering head with fork upper
bracket (6) attached. Carefully position assembly out of
the way. Exercise caution to avoid damaging control
cables, wiring harnesses, clutch cable or brake lines.
NOTE
It is not necessary to disconnect clutch and brake hand levers,
wiring harnesses or control cables from handlebar, unless the
handlebar assembly is to be removed from the motorcycle.
4.
Remove upper seal (5) and upper bearing cone (3). Slide
fork stem and lower bracket (1) from frame.
1
12
2
6
3
4
13
4
3
5
7
10
9
8
11
sm01817
1.
Front fork stem and lower bracket
2.
Seal, lower
3.
Bearing cone (2)
4.
Bearing cup (2)
5.
Seal, upper
6.
Front upper bracket
7.
Fork stem pinch screw
8.
Washer
9.
Fork stem bolt
10. Fork stem bolt cap (XL 1200R/L only)
11. Pinch screw, upper (2)
12. Pinch screw, lower (2)
13. Steering head (part of frame)
Figure 2-201. Fork Stem and Bracket Assembly: Typical
CLEANING, INSPECTION AND REPAIR
TOOL NAME
PART NUMBER
UNIVERSAL DRIVER HANDLE
HD-33416
STEERING HEAD BEARING RACE
REMOVAL TOOL
HD-39301-A
1.
. Clean the seals (2, 5), bearing cones
(3), fork stem and lower bracket (1) and steering head (13)
with solvent.
2-126 2009 Sportster Service: Chassis
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