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Harley Davidson Sportster Models 2009. Service Repair Manual - page 30

REMOVAL

NOTE

The oil pump can be removed with engine in frame and without
removing gearcase cover.

Drain oil from oil tank.

NOTE

See

Figure 3-166

. Do not remove oil pump feed fitting (2) from

the pump (1). Hold oil pump feed fitting and loosen large high
pressure hose fitting nut (3). Then remove high pressure hose
(4) from oil pump feed fitting.

See

Figure 3-166

. Remove high pressure feed hose (4)

from oil pump (1).

sm01486

Oil pump

Oil pump feed fitting

High pressure hose fitting nut

High pressure feed hose (to oil filter)

Figure 3-166. Oil Pump Feed Hose

NOTE

See

Figure 3-165

. The oil pump is designed to be removed as

a complete assembly by removing the two long screws (2) at
opposite corners of the pump. The other two screws (3) hold
the pump together so that it may be removed and installed as
a unit.

See

Figure 3-165

. Carefully remove two screws (2) that

secure oil pump to crankcase. Pump will drop with screws
removed. Discard mounting gasket (15).

Disconnect and tag the two remaining oil hoses from the
pump.

DISASSEMBLY

See

Figure 3-165

. Remove two Torx screws (3). Lift cover

(1) off body (12). Remove and discard o-ring (11).

Slide both pieces of feed gerotor set (6), separator plate
(7) and both pieces of scavenge gerotor set (8) off gear
shaft (14).

Remove and discard retaining ring (9). Remove thrust
washer (10) and gear shaft.

CLEANING AND INSPECTION

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 all parts in cleaning solvent. Blow out holes and oil
passages with compressed air.

See

Figure 3-167

. Inspect both gerotor sets for wear.

Mesh pieces of each set together as shown.

Use a feeler gauge to determine clearance.

The SERVICE WEAR LIMIT between gerotors is
0.004 in. (0.102 mm). Replace gerotors as a set if
clearance exceeds this dimension.

Measure thickness of feed gerotors with a micrometer.
Replace gerotors as a set if they are not the same
thickness.

sm03409

Outer gerotor

Inner gerotor

Wear limit

Figure 3-167. Gerotor Wear Limits

ASSEMBLY

NOTE

Liberally coat all moving parts with clean engine oil to ensure
easy assembly and smooth operation at start-up.

See

Figure 3-165

. Install gear shaft (14) through oil pump

body (12). Position thrust washer (10) over end of shaft.
Install new retaining ring (9) into groove in shaft.

Insert inner gerotor of the scavenge gerotor set (8) over
gear shaft.

Place outer gerotor over inner to complete scavenge set.

Position separator plate (7) into case and line up slots on
perimeter with tabs inside oil pump body.

Place feed gerotor set (6) over gear shaft.

Install a new o-ring (11) into groove in oil pump cover (1).
Place cover onto pump body. Install two Torx cover screws
(3). Tighten to 70-80 in-lbs (7.9-9.0 Nm).

HOME

2009 Sportster Service: Engine 3-131

INSTALLATION

See

Figure 3-165

. Place new mounting gasket (15) in

position.

Secure pump to crankcase with two screws (2). Tighten
to 125-150 in-lbs (14.1-16.9 Nm).

NOTE

Use new hose clamps to secure oil tank feed hose and vent
hose to oil pump fittings. If fittings were removed, use TEFLON
PIPE SEALANT or HYLOMAR on fitting threads.

Install hoses on oil pump. Attach oil tank feed hose to hose
fitting (5) with new clamp. Attach oil tank vent hose to
elbow fitting (13) with new clamp.

See

Figure 3-166

. If oil pump feed fitting (2) was removed

for any reason, install fitting in oil pump (1) cover. Tighten
to 55-65 in-lbs (6.2-7.4 Nm).

If high pressure feed hose (4), was removed completely,
install end opposite high pressure fitting nut (3) in crank-
case. Tighten to 60-90 in-lbs (6.8-10.2 Nm).

Install high pressure feed hose fitting nut (3) onto feed fit-
ting on front of oil pump. Hold oil pump feed fitting with a
wrench and tighten high pressure hose fitting nut to 85-
105 in-lbs (9.6-11.8 Nm).

Fill oil tank with proper oil. See

1.6 ENGINE OIL AND

FILTER

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3-132 2009 Sportster Service: Engine

3.25

OIL PUMP: XR MODELS

GENERAL

The oil pump seldom needs servicing. Before you disassemble
an oil pump suspected of not producing adequate oil pressure,
be sure that all possible related malfunctions have been elim-
inated.

Make sure all oil line connections are tight and that lines
are not pinched or damaged.

Check level and condition of oil in tank. Pressure will be
affected if oil is diluted. In freezing weather, proper circu-
lation of oil can be affected if the oil feed line becomes
clogged with ice or sludge.

Check for a grounded oil pressure switch wire [120] or
faulty switch if oil pressure indicator light fails to go out
with engine running.

See

3.8 ENGINE LUBRICATION SYSTEM

3.27 OIL TANK

and

6.36 OIL PRESSURE SWITCH

for additional information.

HOME

2009 Sportster Service: Engine 3-133

sm05382

21.

11.

Line connector fitting, oil to
cooler

Oil pump/gearcase housing

Oil pump rotor cover

12.

O-rings, rotor cover

O-ring

22.

13.

Thermostat (oil from cooler)

Check valve housing, cylinder
head oil

Retainer

23.

O-ring, internal (1 each fitting)

Plugs

14.

24.

O-ring

Bypass valve shuttle

Line connector fitting, return
oil

25.

15.

Spring, bypass valve

Fastener (2)

16.

O-ring, external (1 each fitting)

26.

Plug

O-ring

27.

17.

Plug

O-ring

Scavenge gerotor set

28.

18.

Feed gerotor set

Fastener (6)

Spring

19.

Check ball

Line connector fitting, supply
oil

20. Gasket

10. Vent line fitting

Figure 3-168. Oil Pump: XR Models

DISASSEMBLY

NOTE

The oil pump can be removed with engine in frame and without
removing gearcase cover.

Drain oil from oil tank.

Place pan under oil pump to collect oil.

See

Figure 3-169

. Remove nine fasteners (1) and remove

gearcase and oil pump cover (2).

See

Figure 3-170

. Remove oil cooler rigid lines (3) from

gearcase cover. See

3.14 PRECISION COOLING

SYSTEM: XR MODELS, Oil Pump Lines

Remove six screws (1) and remove oil pump cover (2).
Discard cover o-rings.

HOME

3-134 2009 Sportster Service: Engine

NOTE

If oil pump rotors are to be re-used, they must be installed in
the original location and orientation as when they are removed.
Failure to do so can result in accelerated wear and possible
engine failure.

See

Figure 3-171

. Wipe the oil film from the exposed sur-

faces of the rotors (1, 2) and mark each rotor using a
permanent marker to aid in reassembly.

NOTE

The surface tension of the remaining oil film will make the rotors
"stick" against the bottom of the bore. Never use a metallic tool
to remove oil pump rotors because damage may result,
requiring that the rotors or gearcase cover be replaced with
new parts.

Grasp the outer rotor (1) of each stage and pull from
housing bore.

Remove each inner rotor (2).

Remove the thermostat fitting (3) and spring.

10. Remove the plug and bypass valve components (4).

11. If necessary, remove remaining line connector fittings from

gearcase cover.

12. Remove and discard all used o-rings.

sm05003

Fastener (9)

Cover

Figure 3-169. Oil Pump Cover: XR Models

sm05018

Oil pump cover screw (6)

Oil pump rotor cover

Oil cooler rigid lines

Figure 3-170. Oil Pump Rotor Cover: XR Models

sm05019

Outer rotor

Inner rotor

Thermostat

Bypass valve plug and components

Figure 3-171. Oil Pump: XR Models

CLEANING AND INSPECTION

Clean all parts in cleaning solvent. Blow out holes and oil
passages with compressed air.

HOME

2009 Sportster Service: Engine 3-135

See

Figure 3-172

. Inspect both gerotor sets for wear.

Mesh pieces of each set together as shown.

Use a feeler gauge to determine clearance.

The SERVICE WEAR LIMIT between gerotors is
0.004 in. (0.102 mm). Replace gerotors as a set if
clearance exceeds this dimension.

Measure thickness of feed gerotors with a micrometer.
Replace gerotors as a set if they are not the same
thickness.

See

Figure 3-173

. Inspect thermostat spring for distortion

or cracks. Inspect rubber seal for damage. Replace ther-
mostat assembly as necessary.

sm03409

Outer gerotor

Inner gerotor

Wear limit

Figure 3-172. Gerotor Wear Limits

sm05659

Figure 3-173. Thermostat: XR Models

ASSEMBLY

NOTE

Used o-rings can leak. Always install new o-rings when per-
forming repairs.

Install new internal o-rings in each line connector fitting.

Install new external o-rings on all connector fittings that
have been removed.

NOTE

Apply a light coat of new engine oil to the shuttle valve compon-
ents and oil pump rotors during assembly.

See

Figure 3-171

. Install bypass valve components (4).

Tighten plug to 108-156 in-lbs (12.2-17.6 Nm).

Install thermostat and oil cooler line fitting (3).

NOTE

If oil pump rotors are to be re-used, they must be installed in
the original location and orientation as when they were
removed. Make sure the mark made during disassembly is
visible when installing the rotors. Failure to do so can result in
accelerated wear and possible engine failure.

Install each outer rotor (1) in its original location.

Install each inner rotor (2) in its original location.

See

Figure 3-170

. Install new o-rings in oil pump rotor

cover and install cover using six fasteners (1). Tighten
fasteners to 80-110 in-lbs (9.0-12.4 Nm).

Install oil cooler rigid lines (3) to quick connect fittings. See

3.14 PRECISION COOLING SYSTEM: XR MODELS, Oil
Pump Lines

See

Figure 3-174

. Install oil pump/cam support housing

cover. Secure with 9 socket fasteners. Tighten in the
sequence shown to 80-110 in-lbs (9.0-12.4 Nm).

sm05017

Figure 3-174. Oil Pump Cover Torque Sequence: XR Models

HOME

3-136 2009 Sportster Service: Engine

3.26

OIL FILTER MOUNT

GENERAL

Oil is pressure-fed from the oil pump to the oil filter mount via
a hose connection. Oil travels through the filter mount into the
filter via outer filter holes.

Adequate oil pressure activates the oil pressure indicator lamp
switch in the filter mount, which turns off the oil pressure
indicator lamp.

The check ball in the filter adapter opens at:

•

XL Models: 10-13 psi (69-90 kPa) oil pressure.

•

XR Models: 5-7 psi (34-48 kPa) oil pressure.

Filtered oil leaves the filter, flowing past the check ball.

DISASSEMBLY

Remove oil filter. See

1.6 ENGINE OIL AND FILTER

NOTE

The engine oil check valve components are located in the
Precision Cooling System cylinder head feed circuit. See

3.14 PRECISION COOLING SYSTEM: XR MODELS, Cylinder
Head Oil Feed Assembly

for service information.

See

Figure 3-175

. Remove oil filter adapter (1) from oil

filter mount (2).

Remove check ball (3) and spring (4).

XL Models: Remove oil pressure indicator lamp switch
(5).

CLEANING AND INSPECTION

Thoroughly clean all parts in cleaning solvent. Blow out holes
and passages using compressed air.

ASSEMBLY

NOTE

Use TEFLON® PIPE SEALANT or HYLOMAR® on all fittings
installed to oil filter mount.

See

Figure 3-175

. XL Models: Install oil pressure indicator

lamp switch (5). Tighten to 50-70 in-lbs (5.6-7.9 Nm).

Place spring (4) and check ball (3) into threaded hole at
center of mount (2). Push oil filter adapter against ball to
compress spring.

NOTE

The new oil filter adapter has one end coated with pre-applied
LOCTITE on the threads; that end must be installed into the
oil filter mount.

Install threaded end (with LOCTITE) into threaded hole at
center of mount. Tighten oil filter adapter to 96-144 in-lbs
(10.9-16.3 Nm).

sm03432

Oil filter adapter

Oil filter mount (part of right crankcase housing)

Check ball

Spring

Oil pressure indicator lamp switch

Figure 3-175. Oil Filter Mount, Typical (XL model shown)

Connect oil pressure switch wire [120] to oil pressure
indicator lamp switch.

Install oil filter. Fill oil tank with proper oil. See

1.6 ENGINE

OIL AND FILTER, Changing Oil and Filter

HOME

2009 Sportster Service: Engine 3-137

3.27

OIL TANK

OIL HOSE ROUTING: XL MODELS

See

Figure 3-176

. The feed, vent and return ports are located

on the bottom of the oil tank to reduce under seat congestion
A hose routes the oil from the feed port at the lower right front
corner to a fitting on the oil pump.

From the feed section of the oil pump, another feed hose directs
the flow up to the oil filter mount. Eventually, oil drains to the
sump where it collects in the scavenge section of the oil pump.
The return hose routes the oil back to the tank where the cycle
is repeated.

Feed

Vent

Return

sm03423

Filler cap and dipstick

Oil tank

Oil pump

Oil filter

Gear case cover

Figure 3-176. Engine Oil Tank, Oil Filter and Hose Routing Locations: XL Models

OIL LINE ROUTING: XR MODELS

See

Figure 3-177

. The feed, vent and return ports are located

on the bottom of the oil tank to reduce under seat congestion.
A hose routes the oil from the feed port at the lower right front
corner to a fitting on the oil pump.

Oil travels to the feed pump through an internal passage in the
pump housing. The feed pump pushes oil to the oil cooler, oil

filter, and cylinder heads. Oil used for lubricating internal engine
components eventually drains into the sump where the scav-
enge pump collects it and routes it back to the oil tank. Oil used
to cool the cylinder heads joins with return oil from the scav-
enge pump and is also returned to the oil tank. For a more
detailed explanation, see

3.8 ENGINE LUBRICATION

SYSTEM, Oil Flow: XR Models

HOME

3-138 2009 Sportster Service: Engine

sm05028

Cylinder head feed oil lines

Vent line

Return oil to tank

Front cylinder head return oil line

Oil from oil cooler

Supply oil from tank

10.

Return oil manifold

Oil to oil cooler

11.

Engine view, right side

Rear cylinder head return oil line

12.

Return oil from pump

Engine view, left side

Figure 3-177. Engine Oil Line Routing: XR Models

HOME

2009 Sportster Service: Engine 3-139

REMOVAL

Remove seat.

Remove left side cover. See

2.20 LEFT SIDE COVER

Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)

Disconnect negative (-) battery cable from ground stud on
crankcase. Disconnect positive (+) battery cables at bat-
tery. See

1.17 BATTERY MAINTENANCE

Drain oil tank as follows (the oil filter need not be removed
unless it is due to be replaced):

Remove filler cap/dipstick assembly from oil tank.

See

Figure 3-178

. Place a suitable container directly

under the drain hose (1) at the bottom rear of the
engine crankcase. The container must be able to hold
approximately 4 quarts (3.8 liters).

Loosen worm drive clamp (2) and pull drain plug (3)
from end of drain hose. Completely drain engine oil
from oil tank.

Replace drain plug into end of drain hose and tighten
worm drive clamp securely.

Remove right side cover by gently prying bottom lip off
tab on oil tank. Then lift top of cover off two stanchions
molded into top of oil tank.

Remove rear belt guard. See

2.24 BELT GUARD AND

DEBRIS DEFLECTOR

NOTE

For ease of assembly, mark oil tank hoses for identification;
oil feed, drain, vent and return, as they are removed from oil
tank.

See

Figure 3-179

. Remove clamp (18) and disconnect

drain hose (9) from oil tank (1).

Remove clamp (17) from upper end of feed oil hose (8)
and disconnect hose from oil tank.

Remove clamp (16) from upper end of return oil hose (6)
and disconnect hose from oil tank.

10. Remove rear fender. See

2.34 REAR FENDER: ALL XL

MODELS EXCEPT XL 1200N

2.35 REAR FENDER AND

LICENSE PLATE BRACKET: XL 1200N

2.36 REAR

FENDER: XR MODELS

11. See

Figure 3-179

. Remove clamp (16) from upper end of

vent oil hose (7) and disconnect hose from oil tank (1).

12. Remove three screws (5) and remove oil tank from right

side of motorcycle.

11763

Oil tank drain hose

Worm drive clamp

Drain plug

Figure 3-178. Oil Tank Drain Hose

HOME

3-140 2009 Sportster Service: Engine

sm03424

11.

Drain plug

Oil tank

12.

O-ring

Hose clip

13.

Clamp

Filler cap/dipstick

14.

Screw

Lock nut

15.

Elbow fitting

Oil tank mounting screw (3)

16.

Return oil hose

Clamp (3)

17.

Clamp (3)

Vent oil hose

18.

Feed oil hose

Clamp

19.

Oil drain hose sleeve

Drain oil hose

10.

20.

Worm drive clamp

Bracket

Figure 3-179. Engine Oil Tank Assembly: XL Models

HOME

2009 Sportster Service: Engine 3-141

INSTALLATION

NOTE

See

Figure 3-179

. The vent oil hose (7) is composed of a

flexible hose originating at the gearcase cover elbow fitting
(15), mated to a hard plastic line, then another flexible hose at
the oil tank vent fitting.

See

Figure 3-179

. Slide oil tank (1) into position in frame

from right side of vehicle.

Install oil tank mounting screw (5) through bracket (20)
and loosely screw into oil tank to hold tank in place. Install
remaining two mounting screws (5) through frame and
screw into oil tank. Tighten all three fasteners to 36-60 in-
lbs (4.1-6.8 Nm).

Install marked oil vent hose (7), feed hose (8), drain hose
(9) and return hose (6) in their proper locations on oil tank
fittings. Secure with new clamps (16, 17, 18).

Install rear fender. See

2.34 REAR FENDER: ALL XL

MODELS EXCEPT XL 1200N

2.35 REAR FENDER AND

LICENSE PLATE BRACKET: XL 1200N

2.36 REAR

FENDER: XR MODELS

Install rear belt guard. See

2.24 BELT GUARD AND

DEBRIS DEFLECTOR

Install right side cover.

Engage two holes on top of cover onto stanchions on
top of oil tank.

Rotate bottom end of cover downward until bottom
lip of cover snaps in place on tab on bottom of oil
tank.

Fill oil tank and install filler cap/dipstick. See

1.6 ENGINE

OIL AND FILTER, Checking and Adding Oil

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

Connect positive (+) battery cables to battery. Connect
negative (-) battery cable to ground point on engine
crankcase. See

1.17 BATTERY MAINTENANCE

Install left side cover. See

2.20 LEFT SIDE COVER

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

10. Install seat.

HOME

3-142 2009 Sportster Service: Engine

TABLE OF CONTENTS

SUBJECT

............................................................................................................................

PAGE NO.

FUEL SYSTEM

NOTES

4.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

4.4 AIR CLEANER: XL MODELS, Installation

13.6-16.3 Nm

120-144 in-lbs

Air cleaner breather screw

4.4 AIR CLEANER: XL MODELS, Installation

4.1-6.8 Nm

36-60 in-lbs

Air cleaner cover screw

4.4 AIR CLEANER: XL MODELS, Installation

4.5-6.8 Nm

40-60 in-lbs

Air filter screw

4.15 EXHAUST SYSTEM: XL MODELS, Installation

13.6-20.4 Nm

120-180 in-lbs

Brake rod-to-bell crank screw

4.17 FUEL INJECTORS, Installation

23.1-32.6 Nm

17-24 ft-lbs

Cylinder head bracket screw

4.15 EXHAUST SYSTEM: XL MODELS, Installation

10.9-13.6 Nm

96-120 in-lbs

Cylinder head exhaust port nut

4.11 INDUCTION MODULE: XR
MODELS, Installation

29.8-35.3 Nm

22-26 ft-lbs

Cylinder head oil feed flare fitting, Preci-
sion Cooling

4.11 INDUCTION MODULE: XR
MODELS, Installation

17.6-23.0 Nm

13-17 ft-lbs

Cylinder head oil feed line flare nut,
Precision Cooling

4.9 ENGINE TEMPERATURE (ET)
SENSOR, Installation

13.6-19.0 Nm

120-168 in-lbs

Engine temperature sensor

4.21 EVAPORATIVE EMISSIONS CONTROL (CA
MODELS), Charcoal Canister

4.1-6.8 Nm

36-60 in-lbs

EVAP canister clip mounting screw

4.21 EVAPORATIVE EMISSIONS CONTROL (CA
MODELS), Charcoal Canister

4.0-5.1 Nm

35-45 in-lbs

EVAP canister guard screw

4.21 EVAPORATIVE EMISSIONS CONTROL (CA
MODELS), Charcoal Canister

23.1-29.9 Nm

17-22 ft-lbs

EVAP canister mounting bracket screw

4.21 EVAPORATIVE EMISSIONS CONTROL (CA
MODELS), Charcoal Canister

23.1-29.9 Nm

17-22 ft-lbs

EVAP canister mounting bracket screw

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

10.8-13.6 Nm

96-120 in-lbs

Exhaust flange nut

4.15 EXHAUST SYSTEM: XL MODELS, Installation

20.4-25.8 Nm

15-19 ft-lbs

Exhaust pipe clamp (rear) nut

4.15 EXHAUST SYSTEM: XL MODELS, Installation

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket screw

4.7 FUEL TANK: XR MODELS, Assemble Fuel
Tank

4.5-5.1 Nm

40-45 in-lbs

Filler housing screws

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

61.0-67.8 Nm

45-50 ft-lbs

Front muffler mount-to-frame fastener

4.17 FUEL INJECTORS, Installation

6.8 Nm

60 in-lbs

Fuel hose retaining bracket screw

4.18 FUEL PUMP, Assembly

2.1-4.1 Nm

19-36 in-lbs

Fuel pump/sender harness grounding
screw

4.18 FUEL PUMP, Assembly

2.1-4.1 Nm

19-36 in-lbs

Fuel pump bracket mounting screw

4.18 FUEL PUMP, Installation

4.5-5.1 Nm

40-45 in-lbs

Fuel pump module mounting screw

4.7 FUEL TANK: XR MODELS, Installing Fuel Tank

2.7-3.4 Nm

24-30 in-lbs

Fuel tank cover fastener

4.7 FUEL TANK: XR MODELS, Installing Fuel Tank

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank front fastener

4.6 FUEL TANK: XL MODELS, Installing Fuel Tank

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

4.10 INDUCTION MODULE: XL MODELS, Install-
ation

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

4.17 FUEL INJECTORS, Installation

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

4.7 FUEL TANK: XR MODELS, Installing Fuel Tank

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank rear fastener

4.10 INDUCTION MODULE: XL
MODELS, Assembly

6.8 Nm

60 in-lbs

IAC mounting screw

HOME

2009 Sportster Service: Fuel System 4-1

NOTES

TORQUE VALUE

FASTENER

4.11 INDUCTION MODULE: XR
MODELS, Assembly

6.8 Nm

60 in-lbs

IAC mounting screw

4.12 IDLE AIR CONTROL (IAC), Installation: XL
Models

6.8 Nm

60 in-lbs

IAC mounting screw

4.12 IDLE AIR CONTROL (IAC), Installation: XR
Models

6.8 Nm

60 in-lbs

IAC mounting screw (XR models)

4.11 INDUCTION MODULE: XR
MODELS, Installation

27.1-32.5 Nm

20-24 ft-lbs

Induction module cover-to-cylinder head
fastener

4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models

27.1-32.5 Nm

20-24 ft-lbs

Induction module cover-to-cylinder head
fastener

4.11 INDUCTION MODULE: XR
MODELS, Installation

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-induction
module fastener

4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-induction
module fastener

4.11 INDUCTION MODULE: XR
MODELS, Installation

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-wire form
fastener

4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-wire form
fastener

4.10 INDUCTION MODULE: XL MODELS, Install-
ation

9.5-12.2 Nm

84-108 in-lbs

Induction module mounting bracket
screw

4.10 INDUCTION MODULE: XL
MODELS, Assembly

4.0 Nm

35 in-lbs

Induction module-to-intake manifold
screw

4.10 INDUCTION MODULE: XL
MODELS, Assembly

6.8 Nm

60 in-lbs

Induction module-to-intake manifold
screw

4.10 INDUCTION MODULE: XL MODELS, Install-
ation

10.9-13.6 Nm

96-120 in-lbs

Intake manifold mounting screw

4.11 INDUCTION MODULE: XR
MODELS, Installation

10.9-13.6 Nm

96-120 in-lbs

Intake manifold mounting screw

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

40.7-44.7 Nm

30-33 ft-lbs

Interconnect bracket-to-frame fastener

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

40.7-44.7 Nm

30-33 ft-lbs

Lower muffler mount nut

4.15 EXHAUST SYSTEM: XL MODELS, Installation

40.7-44.8 Nm

30-33 ft-lbs

Muffler interconnect bracket mounting
screw

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

16.9-20.3 Nm

120-180 in-lbs

Muffler-to-front muffler mount fastener

4.15 EXHAUST SYSTEM: XL MODELS, Installation

20.4-25.8 Nm

15-19 ft-lbs

Muffler-to-interconnect bracket screw

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

16.9-20.3 Nm

120-180 in-lbs

Muffler-to-muffler bolt

4.15 EXHAUST SYSTEM: XL MODELS, Installation

51.6-58.4 Nm

38-43 ft-lbs

Muffler torca clamp nut

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

16.9-20.3 Nm

120-180 in-lbs

Muffler-to-rear muffler mount fastener

4.15 EXHAUST SYSTEM: XL MODELS, Installation

39.3-59.7 Nm

29-44 ft-lbs

O2 sensor

4.14 OXYGEN SENSOR, Installation

39.3-59.7 Nm

29-44 ft-lbs

Oxygen sensor

4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion

20.3-27.1 Nm

15-20 ft-lbs

Rear muffler mount-to-frame fastener

4.15 EXHAUST SYSTEM: XL MODELS, Installation

9.0-13.6 Nm

80-120 in-lbs

Sprocket cover screw: XL models

4.11 INDUCTION MODULE: XR
MODELS, Assembly

6.8 Nm

60 in-lbs

Throttle cable bracket screw: XR models

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4-2 2009 Sportster Service: Fuel System

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