Harley Davidson Sportster Models 2009. Service Repair Manual — page 6

1.8

BLEEDING HYDRAULIC BRAKE SYSTEM

GENERAL

Bleed the hydraulic brake system any time a hydraulic brake
line, brake master cylinder or brake caliper has been opened,
or whenever brake lever/pedal operation feels "spongy."
Bleeding evacuates air from the system leaving only incom-
pressible hydraulic fluid.

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

NOTE

Hydraulic brake fluid bladder-type pressure equipment can be
used to fill brake master cylinders through the bleeder valve.
Remove master cylinder reservoir cover so that system cannot
pressurize. Do not use pressure bleeding equipment when the
hydraulic system is sealed with master cylinder reservoir cover
and diaphragm in place.

BLEEDING FRONT BRAKE: ALL MODELS

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTES

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Cover handlebar switches with a shop towel before adding
brake fluid to front master cylinder reservoir. Spilling brake
fluid on handlebar switches may render them inoperative.

1.

See

Figure 1-9

. Position motorcycle so that top of front

master cylinder reservoir (1) is level.

2.

See

Figure 1-10

. Remove reservoir cover (4) with two

captive screws (5), diaphragm plate (3) and diaphragm
(2) from master cylinder reservoir (1).

1

3

2

sm01420

1.

Front brake master cylinder and reservoir

2.

Cover screw (2)

3.

Top cover

Figure 1-9. Front Brake Master Cylinder Reservoir (typical;

XL model shown)

5

4

1

3

2

sm01421

1.

Front brake master cylinder assembly

2.

Diaphragm

3.

Diaphragm plate

4.

Reservoir cover

5.

Captive screw (2)

Figure 1-10. Front Brake Master Cylinder Cover Assembly

(Typical)

HOME

1-20 2009 Sportster Service: Maintenance

NOTES

•

See

Figure 1-11

. Do not use sight glass (2) to determine

maximum fluid level. Sight glass should only be used as
a visual indicator that fluid level is low and needs attention.
A ridge (1) is cast into the inside of the reservoir to assist
you in determining the correct level.

•

Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.

•

Do not overfill reservoir. Do not reuse old brake fluid.

1

2

sm01422

1.

Cast-in ridge

2.

Sight glass

Figure 1-11. Filling Front Master Cylinder Reservoir

(Typical)

3.

See

Figure 1-11

. Add enough HARLEY-DAVIDSON D.O.T.

4 BRAKE FLUID to reservoir to bring fluid level even with
ridge (1) cast into inside of reservoir, about 1/4-in. (6.35
mm) below top edge.

4.

See

Figure 1-12

or

Figure 1-13

. Remove bleeder cap (3)

from bleeder valve (2) on front caliper (1).

5.

See

Figure 1-14

. Install end of a length of 5/16 in. (7.9

mm) I.D. clear plastic tubing over caliper bleeder valve.
Place free end of tube in a clean container.

6.

Squeeze and hold brake lever to build up hydraulic pres-
sure. See

Figure 1-12

. Open bleeder valve (2) about 1/2-

turn. Brake fluid will flow from bleeder valve through tubing.
Observe fluid flowing through tubing. Check for air bubbles.

7.

Close bleeder valve when brake lever has moved 1/2 to
3/4 of its full range of travel. Allow brake lever to return
slowly to its released position.

8.

Repeat two previous steps until all air bubbles are purged
from system.

9.

Final tighten bleeder valve to 35-61 in-lbs (4.0-6.9 Nm).
Remove plastic tubing and install bleeder cap (3).

10. See

Figure 1-11

. Add enough HARLEY-DAVIDSON D.O.T.

4 BRAKE FLUID to reservoir to bring fluid level even with
ridge cast into inside of reservoir, about 1/4-in. (6.35 mm)
below top edge.

1

2

3

sm01423

1.

Front brake caliper

2.

Bleeder valve

3.

Bleeder cap

Figure 1-12. Front Brake Caliper: XL Models

2

3

1

sm05261

1.

Front brake caliper

2.

Bleeder valve

3.

Bleeder cap

Figure 1-13. Front Caliper Assembly: XR Models

HOME

2009 Sportster Service: Maintenance 1-21

sm01424

Figure 1-14. Bleeding Hydraulic System (typical; XL model

shown)

11. If bleeding vehicle equipped with dual front disc brake

system, repeat this procedure for other caliper.

12. See

Figure 1-10

. Replace diaphragm (2), diaphragm plate

(3) and reservoir cover (4) with captive screws (5). Tighten
to 9-17 in-lbs (1.0-2.0 Nm).

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

13. Test ride motorcycle at low speed. Repeat the above

bleeding procedure if front brake feels spongy.

BLEEDING REAR BRAKE: ALL MODELS

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTES

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

See

Figure 1-15

or

Figure 1-16

. Vehicle must be upright

so that rear brake master cylinder reservoir (1) is in a level
position when filling and checking fluid level.

•

Reservoir cover (5) may be removed from rear brake
master cylinder reservoir to more easily verify fluid level
in reservoir.

•

Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.

•

Do not overfill reservoir. Do not reuse old brake fluid.

1.

Position motorcycle upright (not resting on jiffy stand). See

Figure 1-15

or

Figure 1-16

. Remove reservoir cap (2).

2.

If desired, remove reservoir cover (5) by grasping cover
and gently pull straight out from reservoir (1).

3.

Add HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID to
master cylinder reservoir (1) until the fluid reaches the
upper fluid level (3).

4.

See

Figure 1-17

or

Figure 1-18

. Remove bleeder cap (3).

Install end of a length of 5/16 in. (7.9 mm) I.D. clear plastic
tubing over caliper bleeder valve (2). Place free end of
tube in a clean container.

5.

Depress and hold brake pedal to build up hydraulic pres-
sure. Open bleeder valve about 1/2-turn. Brake fluid will
flow from bleeder valve through tubing. Observe fluid
flowing through tubing. Check for air bubbles.

6.

Close bleeder valve when brake pedal has moved 1/2 to
3/4 of its full range of travel. Allow brake pedal to return
slowly to its released position.

7.

Repeat two previous steps until all air bubbles are purged.

8.

Final tighten bleeder valve to 35-61 in-lbs (4.0-6.9 Nm).
Remove plastic tubing and install bleeder cap.

9.

See

Figure 1-15

or

Figure 1-16

. Add HARLEY-DAVIDSON

D.O.T. 4 BRAKE FLUID to master cylinder reservoir (1)
until the fluid reaches the upper fluid level (3).

10. Replace reservoir cap (2). Replace reservoir cover (5) if

removed.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

11. Test ride motorcycle at low speed. Repeat the above

bleeding procedure if rear brake feels spongy.

HOME

1-22 2009 Sportster Service: Maintenance

2

4

3

5

2

1

4

3

sm01425

1.

Rear brake master cylinder reservoir

2.

Reservoir cap

3.

Upper fluid level

4.

Lower fluid level

5.

Reservoir cover

Figure 1-15. Rear Brake Master Cylinder Reservoir: XL

Models

2

1

3

4

sm05262

1.

Rear brake master cylinder reservoir

2.

Reservoir cap

3.

Upper fluid level

4.

Lower fluid level

Figure 1-16. Rear Brake Master Cylinder Reservoir (XR

Models)

1

3

2

sm03589

1.

Rear brake caliper

2.

Bleeder valve

3.

Bleeder cap

Figure 1-17. Rear Brake Caliper: XL Models

2

1

3

sm05263

1.

Rear brake caliper

2.

Bleeder valve

3.

Bleeder cap

Figure 1-18. Rear Brake Caliper: XR Models

HOME

2009 Sportster Service: Maintenance 1-23

31

46

60

3

1

2

4

sm01530

1.

Valve seat

2.

Valve

3.

Margin

4.

0.040-0.062 in. (1.016-1.575 mm)

Figure 3-130. Intake and Exhaust Valve and Seat

Dimensions

Replacing Valve Seats

Replacing a valve seat is a complex operation requiring special
equipment. If the valve seat is loose or is not fully seated in
the head, then valve seat movement will prevent the proper
transfer of heat from the valve. The valve seat surface must
be flush with (or below) the head surface. See

3.2 SPECIFIC-

ATIONS

for valve seat-to-cylinder head fit.

ASSEMBLY

TOOL NAME

PART NUMBER

VALVE SPRING COMPRESSOR

HD-34736-B

1.

Apply a liberal amount of engine oil to the valve stem.

2.

See

Figure 3-131

. Insert valve (11) into valve guide (7)

and bottom valve on valve seat (12).

HOME

3-110 2009 Sportster Service: Engine

14

15

3

4

5

6

16

7

1

2

18

17

13

9

10

11

12

8

sm01504

10.

1.

Cylinder head gasket

Head bolt, short (2)

2.

11.

Head bolt, long (2)

Valve (1) intake, (1) exhaust

12.

3.

Valve seat (2)

Valve collar retainer (4)

4.

13.

Upper valve spring collar (2)

Cylinder head bracket*

14.

5.

Screw (2)*

Valve spring (2)

6.

15.

Valve seal and lower valve spring collar assembly
(2)

Washer (2)*

16. Stabilizer link bracket (front cylinder head only)

7.

17.

Valve guide, intake and exhaust (2)

Screw (2)

18.

8.

Lock washer (2)

Cylinder head

9.

Exhaust port stud (2)

Figure 3-131. Cylinder Head Assembly (typical) (* Vehicles with Side Mounted Horn Only)

3.

See

Figure 3-132

. Place a protective sleeve over the valve

stem keeper groove. Coat the protective sleeve with oil.

HOME

2009 Sportster Service: Engine 3-111

1.9

BRAKE PADS AND DISCS: XL MODELS

INSPECTION

Brake Pads

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

See

Figure 1-19

. Replace brake pads (3) if brake pad friction

material on either the front or rear caliper is worn to 0.04 in.
(1.02 mm) or less above the backing plate (4). Always replace
both pads in a caliper as a set. See

1.9 BRAKE PADS AND

DISCS: XL MODELS, Brake Pad Replacement: Front

or

1.9 BRAKE PADS AND DISCS: XL MODELS, Brake Pad
Replacement: Rear

.

When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage or leakage.

Brake Disc Thickness, Lateral Runout and
Warpage

The minimum brake disc (2) thickness is stamped on the side
of the disc. Replace disc if worn past minimum thickness or
badly scored.

Maximum brake disc lateral runout and warpage is 0.008 in.
(0.2 mm) when measured near the outside diameter.

•

To replace front brake disc(s), see

2.4 WHEELS, Front

Wheel

.

•

To replace rear brake disc, see

2.4 WHEELS, Rear Wheel

.

4

4

5

1

3

3

2

2

4

4

3

3

sm01427

1.

Front brake caliper (viewed from below)

2.

Brake disc

3.

Brake pad (2)

4.

Brake pad backing plate (2)

5.

Rear brake caliper (viewed from rear)

Figure 1-19. Brake Pad Inspection (Top: Front Brake,

Bottom: Rear Brake)

HOME

1-24 2009 Sportster Service: Maintenance

BRAKE PAD REPLACEMENT: FRONT

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTES

•

Do not remove front caliper(s) from mounting bracket
unless caliper mounting pins require service. Removing
caliper from mounting bracket unnecessarily increases
the risk of contaminants falling into mounting pin holes
and damaging caliper during vehicle operation.

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Cover handlebar switches with a shop towel before adding
brake fluid to front master cylinder reservoir. Spilling brake
fluid on handlebar switches may render them inoperative.

1.

See

Figure 1-20

. Position motorcycle so that front master

cylinder reservoir (1) is level.

2.

See

Figure 1-21

. Remove two screws (5), reservoir cover

(4), diaphragm plate (3) and diaphragm (2) from master
cylinder reservoir (1).

1

3

2

sm01420

1.

Front brake master cylinder and reservoir

2.

Cover screw (2)

3.

Top cover

Figure 1-20. Front Brake Master Cylinder Reservoir (typical;

XL model shown)

NOTE

As the pistons are pushed back into the caliper, fluid level may
rise higher than fluid level mark at about 1/4-in. (6.35 mm)
below top of reservoir. You may have to remove fluid to allow
for this.

3.

Press against the side of the brake caliper body to push
the outside brake pad (pad closest to caliper pistons) back.
This pushes the caliper pistons back into their bores.

5

4

1

3

2

sm01421

1.

Front brake master cylinder assembly

2.

Diaphragm

3.

Diaphragm plate

4.

Reservoir cover

5.

Captive screw (2)

Figure 1-21. Front Brake Master Cylinder Cover Assembly

(Typical)

NOTES

•

See

Figure 1-22

. When replacing front brake pads, make

sure pad spring does not become dislodged and fall out.
If it does, you will have to reinstall it before installing new
pads.

•

The front left and front right (not present on all models)
calipers do NOT use the same brake pad set as the rear
brake caliper.

HOME

2009 Sportster Service: Maintenance 1-25

sm01428

Figure 1-22. Front Caliper Pad Spring

4.

See

Figure 1-23

. Remove pad pin plug (3).

5.

See

Figure 1-24

. Loosen, but do not remove, brake pad

pin.

NOTE

Do not completely remove brake pad pin from caliper during
the next step. Completely removing pad pin at this time may
cause difficulty during assembly.

6.

Once the pistons have been fully retracted into their bores,
pull pad pin part way until inside pad drops free. Note the
pad's original orientation for replacement purposes.

2

1

3

4

sm01429

1.

Front brake caliper

2.

Caliper mounting bracket

3.

Pad pin plug

4.

Caliper mounting pins

Figure 1-23. Front Caliper Assembly

sm01430

Figure 1-24. Brake Pad Pin (Plug Removed)

7.

See

Figure 1-25

. Install new inside brake pad (1) using

same orientation as pad previously removed. Make sure
front mounting tab (2) is seated in slot (5) in caliper
mounting bracket (4) and pad friction material faces brake
disc.

8.

While holding new inside pad in place, pull pad pin out
and remove outside brake pad. Note the pad's original
orientation for replacement purposes.

9.

Install new outside brake pad using the same orientation
as pad previously removed. Make sure front mounting tab
is seated in slot in caliper mounting bracket and pad friction
material faces brake disc.

10. Temporarily insert a 1/8-in drill bit in caliper pad pin hole

to hold both pads in place.

11. Inspect pad pin for grooving and wear. Measure pad pin

diameter in an unworn area, and then in the area of any
grooving or wear. If wear is more than 0.011 in. (0.28 mm),
replace pin.

3

1

1

3

2

2

4

5

sm01431

1.

Brake pad

2.

Front mounting tab

3.

Pad pin hole

4.

Front caliper mounting bracket

5.

Slot

Figure 1-25. Front Brake Pads

HOME

1-26 2009 Sportster Service: Maintenance

12. Press brake pads firmly up against pad spring, remove

drill bit and install pad pin. Tighten to 131-173 in-lbs (14.8-
19.6 Nm).

NOTE

If pad pin does not fit, check the following:

•

You are using a set of pads, not two identical pads.

•

Pad spring orientation must match

Figure 1-22

.

•

See

Figure 1-25

. Pad front mounting tabs (2) must be fully

seated in mounting bracket slot (5).

•

Pads must be pushed tight up against pad spring before
pad pin is installed.

13. See

Figure 1-23

. Install pad pin plug (3). Tighten to 18-25

in-lbs (2.0-2.9 Nm).

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

14. Pump brake lever to move pistons out until they contact

outside brake pad. Verify piston location against pad.

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

15. See

Figure 1-26

. Check brake fluid level in master cylinder.

Add enough HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
to reservoir to bring fluid level even with ridge (1) cast into
inside of reservoir, about 1/4-inch (6.35 mm) below top
edge.

1

2

sm01422

1.

Cast-in ridge

2.

Sight glass

Figure 1-26. Filling Front Master Cylinder Reservoir

(Typical)

16. See

Figure 1-21

. Install diaphragm (2), diaphragm plate

(3), reservoir cover (4) and screws (5) on front brake
master cylinder reservoir. Tighten screws to 9-17 in-lbs
(1.0-2.0 Nm).

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

17. Test brake system.

a.

Turn ignition switch ON. Pump brake lever to verify
operation of the brake lamp.

b.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

.

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

BRAKE PAD REPLACEMENT: REAR

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTES

•

Do not remove rear caliper from mounting bracket unless
caliper mounting pins and boots require service. Removing
caliper from mounting bracket unnecessarily increases
the risk of contaminants falling into caliper boots and

HOME

2009 Sportster Service: Maintenance 1-27