Harley Davidson Sportster 2009 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster Year: 2009 Generation Sportster Generation: XL (Evolution Engine) Codes Vin Character Start: 5 👋 Introduction Market Position Segment: Cruiser Motorcycle Target Audience:...

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UGS: 59729

Mots clés: 2009 Harley Davidson Misc Motorcycle Motorcycles Sportster

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster

Year:

Generation

Sportster Generation:

XL (Evolution Engine)

Codes

Vin Character Start:

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Harley-Davidson Sportster owners, independent mechanics, enthusiast workshops

Competitive Analysis

Competitors:

Indian Scout, Triumph Bonneville, Yamaha Bolt

Key Features

Model Identity:

Iconic American motorcycle known for its distinctive V-twin engine and classic styling

Engine Heritage:

Evolution engine, a long-standing and reliable power plant for Harley-Davidson

📋 Manual Details

Coverage Areas

Manual Scope:

Complete Service, Repair, and Workshop Procedures

Page Count

Estimated Pages:

Hundreds (typically 500+ for a comprehensive manual)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Evolution V-Twin Engine (883cc, 1200cc variants), Engine disassembly, assembly, troubleshooting, diagnostics

Fuel System:

Carburetor (Keihin CV), Fuel injection (EFI - for applicable models), Fuel tank, fuel pump, fuel lines, troubleshooting

Ignition System:

Ignition module, spark plugs, coils, timing, troubleshooting

Transmission:

5-speed Gearbox, Clutch operation, primary drive, troubleshooting, rebuild procedures

Drivetrain:

Belt drive, rear sprocket, primary drive chain, inspection, adjustment, replacement

Suspension:

Front forks (conventional), rear shock absorbers, fork oil change, seal replacement, shock absorber adjustment/replacement

Brakes:

Front and rear disc brakes, brake calipers, master cylinders, brake fluid flush and replacement, bleeding procedures, pad replacement

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting, horn, fuses, relays, troubleshooting electrical faults

Chassis And Frame:

Frame inspection, headstock bearing adjustment, swingarm maintenance, wheel bearing replacement

Bodywork And Trim:

Fender removal/installation, fuel tank mounting, seat removal, handlebar and control adjustments

Diagnostics:

Troubleshooting charts for common problems, diagnostic procedures, fault code interpretation (if applicable to EFI models)

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, chain adjustments, lubrication points, tune-up procedures

Engine Repair:

Top-end rebuilds, bottom-end rebuilds, valve adjustments, piston and ring replacement, cylinder head service

Transmission Repair:

Clutch adjustments, gear shift linkage, primary drive inspection, transmission disassembly and reassembly

Brake Maintenance:

Brake fluid replacement, caliper servicing, pad replacement, line inspection

Electrical Troubleshooting:

Wiring diagram interpretation, component testing, circuit diagnosis

Fork Rebuild:

Front fork seal replacement, oil level checks and changes

Wheel And Tire:

Tire pressure checks, wheel bearing replacement, spoke tensioning (if applicable)

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds

Diagnostic Capability:

Detailed diagnostic procedures and troubleshooting flowcharts

Component Level Detail:

Detailed diagrams and specifications for individual components

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content for quick information retrieval

Printability:

Printable pages for workshop use

Print Quality

Image Resolution:

High-resolution diagrams and illustrations

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

Available in 883cc (53.9 cu in) and 1200cc (73.3 cu in) variants

Bore X Stroke 883:

76.2 mm x 96.8 mm (3.00 in x 3.81 in)

Bore X Stroke 1200:

88.9 mm x 96.8 mm (3.50 in x 3.81 in)

Compression Ratio 883:

8.8:1

Compression Ratio 1200:

9.7:1

Valve Train:

Pushrod-actuated, overhead valves, two valves per cylinder

Performance

Horsepower 883:

Approx. 50-55 HP (estimated)

Torque 883:

Approx. 55-60 lb-ft (estimated)

Horsepower 1200:

Approx. 65-70 HP (estimated)

Torque 1200:

Approx. 70-75 lb-ft (estimated)

Fuel System

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI) or Keihin CV Carburetor depending on model variant

Fuel Type:

Unleaded Gasoline, 91 octane (R+M)/2 or higher recommended

Oil Capacity

Engine Oil Capacity:

3.0 US qt (2.8 L) with filter change

Oil Specification

Engine Oil Type:

Harley-Davidson SYN3 20W-50 or equivalent API SG, Jaso FD, or ACEA A3 certified synthetic motorcycle oil

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Primary Drive:

Duplex chain

Final Drive:

Belt drive

Features

Clutch Type:

Wet, multi-plate

Transmission Oil Capacity:

1 US qt (0.95 L)

Transmission Oil Type:

Harley-Davidson Primary Chain Lubricant or SAE 85W-140 gear oil

📐 Dimensions

Exterior

Length:

Approx. 88.0 in (2235 mm)

Width:

Approx. 33.5 in (851 mm)

Height:

Approx. 46.9 in (1191 mm)

Wheelbase:

Approx. 60.0 in (1524 mm)

Weights

Dry Weight 883:

Approx. 555 lb (252 kg)

Dry Weight 1200:

Approx. 562 lb (255 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 963 lb (437 kg)

Cargo

Fuel Tank Capacity:

3.0 US gal (11.4 L)

🛡️ Safety Features

Ratings

Safety Certification:

Meets FMVSS 208 (USA), CMVSS 208 (Canada) requirements for motorcycle seating positions.

Active Features

Braking System:

Dual-piston front caliper with floating rotor, single-piston rear caliper with solid rotor

Lighting:

Halogen headlamp, LED tail lamp, standard front and rear turn signals

Passive Features

Frame Construction:

Mild steel, tubular frame and swingarm

Ergonomics:

Low seat height for rider confidence and control

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer, tachometer (optional on some models), odometer, trip meter, engine diagnostics indicator

Driver Assistance

Anti-lock Braking System (ABS) was an optional feature on select 2009 Sportster models.

Connectivity

Ignition:

Key ignition with fork lock

🔧 Maintenance

Service Intervals

First Service:

1,000 miles (1,600 km) or 6 months, whichever comes first (typically oil change, primary chain adjustment, inspection)

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months (typically engine oil and filter change, inspections)

Belt Tension Check:

Recommended every 5,000 miles (8,000 km) or as needed

Brake Fluid Flush:

Recommended every 24 months

Fluid Specifications

Fork Oil Type:

Harley-Davidson Suspension Formula or SAE 10W fork oil

Fork Oil Capacity:

Approx. 7.7 US oz (228 ml) per fork leg (check specific model for exact amount)

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Known Issues

Clutch Adjustment:

Clutch lever play and engagement can require frequent adjustment on some models.

Carburetor Tuning:

Keihin CV carburetor may require tuning for optimal performance at different altitudes or with aftermarket exhaust/air filter modifications.

Charging System:

Stator and regulator/rectifier failures can occur over time, impacting battery charging.

Vibration:

Characteristically vibrates due to the V-twin engine configuration; rubber-mounted handlebars and footpegs help mitigate this.

📚 Vehicle History

Brand Heritage

Brand Origin:

Founded in Milwaukee, Wisconsin, USA, in 1903. Pioneer in motorcycle manufacturing.

Model Evolution

Sportster Lineage:

The Sportster line, first introduced in 1957, is one of the longest-running motorcycle model names in history. It has evolved from its early 'K Model' roots into a versatile and customizable platform.

Evolution Engine Introduction:

The Evolution engine, known as the 'Evo', was introduced in 1984, replacing the Shovelhead engine. It has been a staple of Harley-Davidson's lineup since then.

Production

Manufacturing Location:

United States (typically Milwaukee, Wisconsin, or Kansas City, Missouri)

🏆 Awards & Recognition

Recognitions

Legacy:

The Sportster is consistently recognized for its enduring appeal, customization potential, and as a gateway into Harley-Davidson ownership.

Ratings

Customer Satisfaction:

Generally high customer satisfaction, particularly for its iconic styling and V-twin character.