Harley Davidson Sportster Models 2009. Service Repair Manual — page 3

Perform the service and maintenance operations as
indicated in the regular service interval table. Lack of
regular maintenance at the recommended intervals can
affect the safe operation of your motorcycle, which could
result in death or serious injury. (00010a)

Service operations to be performed before customer delivery
are specified in the applicable model year predelivery and set-
up instructions.

The performance of new motorcycle initial service is required
to keep warranty in force and to verify proper emissions sys-
tems operation. See

1.4 MAINTENANCE SCHEDULE

SAFE OPERATING MAINTENANCE

NOTES

•

Do not attempt to retighten engine head bolts. Retightening
can cause engine damage.

•

During the initial break-in period, use only Harley-Davidson
20W50 engine oil. Failure to use the recommended oil will
result in improper break-in of the engine cylinders and
piston rings.

A careful check of certain equipment is necessary after periods
of storage, and frequently between regular service intervals,
to determine if additional maintenance is required.

Check:

Tires for abrasions, cuts and correct pressure.

Secondary drive belt for proper tension and condition.

Brakes, steering and throttle for responsiveness.

Brake fluid level and condition. Hydraulic lines and fittings
for leaks. Also, check brake pads and rotors for wear.

Cables for fraying, crimping and free operation.

Engine oil and transmission fluid levels.

Headlamp, auxiliary lamp, tail lamp, brake lamp, horn and
turn signal operation.

SHOP PRACTICES

Repair Notes

General maintenance practices are given in this section.

NOTES

•

Repair = Disassembly/Assembly.

•

Replacement = Substitute a new part for existing com-
ponent.

All special tools and torque values are noted at the point of
use.

All required parts or materials can be found in the appropriate
PARTS CATALOG.

Safety

Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Protect yourself and bystanders with approved
eye protection. Don't just do the job - do the job safely.

Removing Parts

Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove some
parts. The lengths of chains or cables from the hoist to the part
should be equal and parallel and should be positioned directly
over the center of the part. Be sure that no obstructions will
interfere with the lifting operation. Never leave a part suspended
in mid-air.

Be sure to check capacity rating and condition of hoists,
slings, chains and cables before use. Exceeding capacity
ratings or using lifting devices that are in poor condition
can lead to an accident, which could result in death or
serious injury. (00466c)

Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.

When removing hoses, wiring or tubes, always tag each part
to verify proper installation.

Cleaning

If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, filters
and covers are used in this vehicle to keep out environmental
dirt and dust. These items must be kept in good condition to
guarantee satisfactory operation.

When you are instructed in a step to clean fastener threads or
threaded holes, proceed as follows: Clean all LOCTITE material
from fastener threads and threaded holes. Use a wire brush
to clean fastener threads. Use a thread chaser or other suitable
tool to clean threaded holes. Use PJ-1 cleaner or equivalent
to remove all traces of oil and contaminants from threads. Blow
out all threaded holes with low pressure compressed air.

Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning, cover
all parts with clean lint-free cloth, paper or other material. Be
sure the part is clean when it is installed.

Always clean around lines or covers before they are removed.
Plug, tape or cap holes and openings to keep out dirt, dust and
debris.

Always verify cleanliness of blind holes before assembly.
Tightening a screw with dirt, water or oil in the hole can cause
castings to crack or break.

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1-4 2009 Sportster Service: Maintenance

Disassembly and Assembly

Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Be sure to make all
necessary adjustments. Recheck your work when finished. Be
sure that everything is done.

Operate the vehicle to perform any final check or adjustments.
If all is correct, the vehicle is ready to go back to the customer.

Checking Torques on Fasteners

Attempt to turn the fastener using a torque wrench set to the
minimum torque specification for that fastener. If the fastener
does not rotate, the fastener torque has been maintained. If
the fastener rotates, remove it to determine if it is a lock-patch
type.

If it has a locking agent, clean all locking material from the
threaded hole. Replace the fastener with a new one or clean
the original fastener threads and apply the appropriate Loctite
product (see appropriate procedure). Install and tighten the
fastener to specification.

If the fastener is not lock-patch type, install and tighten to
specification.

Magnetic Parts Trays

Magnetic parts trays are becoming common in the service
facility because they are convenient and can keep parts from
becoming lost during a repair procedure.

However, hardened steel parts can become magnetized when
held in magnetic parts trays. Metal fragments that would
ordinarily be washed away in the oil and trapped in the oil filter
or magnetic drain plug during vehicle operation could be cap-
tured by magnetized parts in the engine, potentially causing
accelerated engine wear and damage.

Parts that will be returned to service inside the vehicle's
powertrain such as gears, thrust washers and especially
bearings should never be kept in magnetic parts trays.

REPAIR AND REPLACEMENT
PROCEDURES

Hardware and Threaded Parts

Install helical thread inserts when inside threads in castings
are stripped, damaged or not capable of withstanding specified
torque.

Replace bolts, nuts, studs, washers, spacers and small
common hardware if missing or in any way damaged. Clean
up or repair minor thread damage with a suitable tap or die.

Replace all damaged or missing lubrication fittings.

Use Teflon pipe sealant or LOCTITE 565 THREAD SEALANT
on pipe fitting threads.

Threadlocking Agents

Always follow specific service manual procedures when working
with fasteners containing preapplied threadlocking agents when
fastener replacement is recommended. When re-using
fasteners containing threadlocking agents, be sure to com-
pletely remove all existing threadlocking agent from fastener
threads with a wire brush or wire wheel. Also, be sure to
remove residual threadlocking agent from fastener hole using
an appropriate thread chasing device and compressed air when

using new or existing fasteners. Always use the recommended
threadlocking agent for your specific procedure.

Wiring, Hoses and Lines

Hoses, clamps, electrical wiring, electrical switches or fuel lines
if they do not meet specifications.

Instruments and Gauges

Replace broken or defective instruments and gauges. Replace
dials and glass that are so scratched or discolored that reading
is difficult.

Bearings

Anti-friction bearings must be handled in a special way. To
keep out dirt and abrasives, cover the bearings as soon as
they are removed from the package.

Wash bearings in a non-flammable cleaning solution. Knock
out packed lubricant inside by tapping the bearing against a
wooden block. Wash bearings again. Cover bearings with clean
material after setting them down to dry. Never use compressed
air to dry bearings.

Coat bearings with clean oil. Wrap bearings in clean paper.

When bearings are installed against shoulders, be sure that
the chamfered side of the bearing always faces the shoulder.
Lubricate bearings and all metal contact surfaces before
pressing into place. Only apply pressure on the part of the
bearing that makes direct contact with the mating part. Install
bearings with numbered side facing out.

Always use the proper tools and fixtures for removing and
installing bearings.

Bearings do not usually need to be removed. Only remove
bearings if necessary.

Bushings

Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings that must be replaced.

When pressing or driving bushings, be sure to apply pressure
in line with the bushing bore. Use a bearing/bushing driver or
a bar with a smooth, flat end. Never use a hammer to drive
bushings.

Inspect the bushing and the mated part for oil holes. Be sure
all oil holes are properly aligned.

Gaskets

Always discard gaskets after removal. Replace with new gas-
kets. Never use the same gasket twice. Be sure that gasket
holes match up with holes in the mating part. But be aware
that sections of a gasket may be used to seal passages.

If a gasket must be made, be sure to cut holes that match up
with the mating part. Serious damage can occur if any flange
holes are blocked by the gasket. Use material that is the right
type and thickness.

Lip Type Seals

Lip seals are used to seal oil or grease and are usually installed
with the sealing lip facing the contained lubricant. Seal orient-
ation, however, may vary under different applications.

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2009 Sportster Service: Maintenance 1-5

Seals should not be removed unless necessary. Only remove
seals if required to gain access to other parts or if seal damage
or wear dictates replacement.

Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.

Always discard seals after removal. Do not use the same seal
twice.

O-Rings (Preformed Packings)

Always discard o-rings after removal. Replace with new o-rings.
To prevent leaks, lubricate the o-rings before installation. Apply
the same type of lubricant as that being sealed. Be sure that
all gasket, o-ring and seal mating surfaces are thoroughly clean
before installation.

Gears

Always check gears for damaged or worn teeth.

Remove burrs and rough spots with a honing stone or crocus
cloth before installation.

Lubricate mating surfaces before pressing gears on shafts.

Shafts

If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.

Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Discard
parts that are worn. Be sure tapered splines are clean, dry and
free of burrs before putting them in place. Press mating parts
together tightly.

Clean all rust from the machined surfaces of new parts.

Part Replacement

Always replace worn or damaged parts with new parts.

Exhaust System Leakage

In the event of an exhaust system leak at a muffler or header
pipe connection location, disassemble and clean all mating
surfaces. Replace any damaged components. If leak still exists,
disassemble and repair the leak by applying a bead of Harley-
Davidson High-Performance Sealant (Part No. 99650-02) (or
an equivalent 02 Sensor/Catalyst-safe alternative). Reassemble
components, wipe off any excess sealant and allow adequate
curing time following sealant product instructions before oper-
ating vehicle.

CLEANING

Part Protection

Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a grease-
proof barrier material. Remove the rubber part if it cannot be
properly protected.

Cleaning Process

Any cleaning method may be used as long as it does not result
in parts damage. Thorough cleaning is necessary for proper
parts inspection. Strip rusted paint areas to bare metal before
priming and repainting.

Rust or Corrosion Removal

Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.

Bearings

Remove shields and seals from bearings before cleaning.
Clean bearings with permanent shields and seals in solution.

Using compressed air to "spin dry" bearings can cause
bearing to fly apart, which could result in death or serious
injury. (00505b)

Clean open bearings by soaking them in a petroleum cleaning
solution. Never use a solution that contains chlorine.

Let bearings stand and dry. Do not dry with compressed air.
Do not spin bearings while they are drying.

TOOL SAFETY

Air Tools

•

Always use approved eye protection equipment when
performing any task using air-operated tools.

•

On all power tools, use only recommended accessories
with proper capacity ratings.

•

Do not exceed air pressure ratings of any power tools.

•

Bits should be placed against work surface before air
hammers are operated.

•

Disconnect the air supply line to an air hammer before
attaching a bit.

•

Never point an air tool at yourself or another person.

•

Protect bystanders with approved eye protection.

Wrenches

•

Never use an extension on a wrench handle.

•

If possible, always pull on a wrench handle and adjust
your stance to prevent a fall if something lets go.

•

Never cock a wrench.

•

Never use a hammer on any wrench other than a
STRIKING FACE wrench.

•

Discard any wrench with broken or battered points.

•

Never use a pipe wrench to bend, raise or lift a pipe.

Pliers/Cutters/Pry bars

•

Plastic- or vinyl-covered pliers handles are not intended
to act as insulation. Do not use on live electrical circuits.

•

Do not use pliers or cutters for cutting hardened wire
unless they were designed for that purpose.

•

Always cut at right angles.

•

Do not use any pry bar as a chisel, punch or hammer.

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1-6 2009 Sportster Service: Maintenance

Hammers

•

Never strike a hammer against a hardened object, such
as another hammer.

•

Always grasp a hammer handle firmly, close to the end.

•

Strike the object with the full face of the hammer.

•

Never work with a hammer which has a loose head.

•

Discard hammer if face is chipped or mushroomed.

•

Wear approved eye protection when using striking tools.

•

Protect bystanders with approved eye protection.

Punches/Chisels

•

Never use a punch or chisel with a chipped or mush-
roomed end; dress mushroomed chisels and punches with
a file.

•

Hold a chisel or a punch with a tool holder if possible.

•

When using a chisel on a small piece, clamp the piece
firmly in a vise and chip toward the stationary jaw.

•

Wear approved eye protection when using these tools.

•

Protect bystanders with approved eye protection.

Screwdrivers

•

Do not use a screwdriver for prying, punching, chiseling,
scoring or scraping.

•

Use the right type of screwdriver for the job; match the tip
to the fastener.

•

Do not interchange POZIDRIV, PHILLIPS or REED AND
PRINCE screwdrivers.

•

Screwdriver handles are not intended to act as insulation.
Do not use on live electrical circuits.

•

Do not use a screwdriver with rounded edges because it
will slip. Redress with a file.

Ratchets and Handles

•

Periodically clean and lubricate ratchet mechanisms with
a light grade oil. Do not replace parts individually; ratchets
should be rebuilt with the entire contents of service kit.

•

Never hammer or put a pipe extension on a ratchet or
handle for added leverage.

•

Always support the ratchet head when using socket
extensions, but do not put your hand on the head or you
may interfere with the action of its reversing mechanism.

•

When breaking loose a fastener, apply a small amount of
pressure as a test to be sure the ratchet's gear wheel is
engaged with the pawl.

Sockets

•

Never use hand sockets on power or impact wrenches.

•

Select the right size socket for the job.

•

Never cock any wrench or socket.

•

Select only impact sockets for use with air or electric
impact wrenches.

•

Replace sockets showing cracks or wear.

•

Keep sockets clean.

•

Always use approved eye protection when using power
or impact sockets.

Storage Units

•

Do not open more than one loaded drawer at a time. Close
each drawer before opening up another.

•

Close lids and lock drawers and doors before moving
storage units.

•

Do not pull on a tool cabinet; push it in front of you.

•

Set the brakes on the locking casters after the cabinet has
been rolled to your workspace.

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2009 Sportster Service: Maintenance 1-7

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