Harley Davidson Sportster Models 2009. Service Repair Manual

Do not install IAC mounting screw on throttle wheel side of
induction module until cable bracket is installed in the next
step. Install other IAC mounting screw but do not tighten at this
time.

Install cable bracket (12) onto induction module. Apply
Loctite Threadlocker 243 (blue) to the threads of screw
(11). Install screw finger-tight. Then tighten both IAC
mounting screws to 60 in-lbs (6.8 Nm). Tighten screw
(11) to 60 in-lbs (6.8 Nm).

Install fuel injectors, fuel rail and fuel hose. See

4.17 FUEL

INJECTORS

INSTALLATION

Make sure the two left side mounting screws are installed
two or three turns into the heads.

See

Figure 4-53

. Install mounting flanges (3) on induction

module with counterbore (1) facing toward the engine.

Place a new seal (4) into each mounting flange with the
beveled edge (2) facing the mounting flange counterbore.
Rotate the flanges so the slotted mounting hole is on the
same side as the IAC solenoid.

NOTE

When induction module is positioned on manifold mounting
screws, be sure the flanges are installed correctly on the
manifold. Also be sure the rubber seals are in place.

See

Figure 4-51

. Place induction module assembly in

position between engine heads. Slide open slotted ends
of mounting flanges under heads of two mounting screws
on left side of engine.

While holding induction module assembly in place, install
two mounting screws (3) into remaining mounting flange
holes. Tighten all four screws finger-tight.

Tighten all four mounting screws to 96-120 in-lbs (10.9-
13.6 Nm).

Inspect o-rings on flare fittings (2) and replace as neces-
sary. Install flare fittings in cylinder heads and tighten to
22-26 ft-lbs (29.8-35.3 Nm).

Connect oil line flare nuts (1) to flare fittings (2) and tighten
to 13-17 ft-lbs (17.6-23.0 Nm).

Install throttle cables. See

2.30 THROTTLE CABLES: ALL

MODELS

10. Adjust throttle and idle cables. See

1.27 THROTTLE

CONTROL

sm05423

Beveled counterbore

Beveled edge

Mounting flange

Tapered seal

Figure 4-53. Mounting Flange and Seal

11. California models only: See

Figure 4-50

. Install purge

hose onto fitting (8) on induction module (1).

HOME

4-36 2009 Sportster Service: Fuel System

12. Plug in the following connectors:

Front fuel injector (3) connector [84],

Rear fuel injector (4) connector [85],

TMAP sensor (5) connector [80],

IAC (6) connector [87],

NOTE

Apply Harley-Davidson Electrical Contact Lubricant part
number 99861-02 to the TPS connector and terminals
prior to connecting to TPS.

TP sensor (7) connector [88].

13. See

Figure 4-49

. Install induction module cover. Secure

TP sensor harness to cover during installation using a new
cable tie with anchor. Install all fasteners finger tight before
final tightening any. Tighten socket head bolts (3) to 20-

24 ft-lbs (27.1-32.5 Nm). Tighten fastener (2) to 84-108
in-lbs (9.5-12.2 Nm). Tighten fastener (1) to 84-108 in-
lbs (9.5-12.2 Nm).

14. Install airbox. See

4.5 AIRBOX: XR MODELS

15. Install fuel tank. See

4.7 FUEL TANK: XR MODELS

16. Fill fuel tank and carefully check for leaks around fuel

pump module and quick connector. See

4.7 FUEL TANK:

XR MODELS

17. Install main fuse and close left side cover. See

6.38 MAIN

FUSE

18. Turn key switch to ON and then back to OFF to reset idle

air control to park position.

19. Start vehicle and check for fuel leaks.

20. Road test vehicle.

HOME

2009 Sportster Service: Fuel System 4-37

4.12

IDLE AIR CONTROL (IAC)

GENERAL

Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)

See

Figure 4-54

. The Electronic Control Module (ECM) uses

the Idle Air Control (IAC) to control engine idle speed.

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the IAC.

sm01628a

Induction module: XL models

Induction module: XR models

IAC

Figure 4-54. Idle Air Control (IAC) Location (Induction

Module Removed From Vehicle for Clarity)

HOME

4-38 2009 Sportster Service: Fuel System

REMOVAL: XL MODELS

TOOL NAME

PART NUMBER

HEAT GUN

HD-25070

NOTE

It is not necessary to remove the fuel tank, induction module
or induction module mounting bracket in order to replace the
IAC.

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

6.38 MAIN FUSE

Remove air cleaner cover, air filter element and backing
plate assembly. See

4.4 AIR CLEANER: XL MODELS

See

Figure 4-55

. Unplug harness connector [87B] from

IAC connector [87A] (1).

NOTE

Screws (2) MUST be heated to soften the thread sealant and
avoid breakage during removal. Use ONLY HEAT GUN (Part
No. HD-25070) to heat the screws. NEVER use an open flame.

Using a six-point socket (not a Torx wrench), remove two
screws (2) in the following order:

Heat fastener nearest to throttle bracket for two
minutes using HEAT GUN (Part No. HD-25070).
Remove screw.

Heat remaining screw for one minute and remove.

See

Figure 4-56

. Grasp IAC and rotate clockwise until IAC

mounting tab (1) clears throttle cable bracket (2).

With a gentle twisting motion, pull IAC straight out of
induction module body.

sm01629

IAC Connector [87A]

Screw (2)

IAC

Throttle cable bracket

Figure 4-55. IAC Removal/Installation (XL Models)

sm01630

IAC mounting tab (2) (rotated 45 degrees)

Throttle cable bracket

Figure 4-56. Removing/Installing IAC (XL Models)

INSTALLATION: XL MODELS

See

Figure 4-57

. If re-using IAC (1), inspect o-ring (2) for

cuts, tears or signs of deterioration. Install new o-ring if
necessary.

Clean all locking agent from the threads of the attachment
screws and holes. Blow debris from screw holes using
low-pressure compressed air.

Apply a thin coat of clean engine oil to o-ring.

Note orientation and position of IAC, shown in

Figure 4-55

Rotate IAC approximately 45 degrees clockwise from this
position (see

Figure 4-56

.) so IAC mounting tab will clear

throttle cable bracket (4) when IAC is installed.

With a gentle twisting motion, insert IAC into induction
module.

Rotate IAC so that harness connector faces intake mani-
fold and mounting tab is underneath tab on throttle cable
bracket.

See

Figure 4-55

. Apply a drop of Loctite Threadlocker and

Sealant 243 (blue) the threads of each screw (2).

Install two screws (2). Using a six-point socket (not a Torx
wrench), tighten to 60 in-lbs (6.8 Nm).

Plug harness connector [87B] into IAC connector [87A]
(1).

10. Install air cleaner backing plate assembly, air filter element

and air cleaner cover. See

4.4 AIR CLEANER: XL

MODELS

11. Install main fuse and close left side cover. See

6.38 MAIN

FUSE

12. Road test vehicle.

HOME

2009 Sportster Service: Fuel System 4-39

sm01632

IAC

O-ring

Pintle

Figure 4-57. IAC and O-ring (All Models)

REMOVAL: XR MODELS

TOOL NAME

PART NUMBER

HEAT GUN

HD-25070

NOTE

It is not necessary to remove the fuel tank, airbox or induction
module from the vehicle in order to replace the IAC.

Gasoline can drain from quick-connect fitting when
removing fuel line. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. Wipe up spilled fuel immediately and dispose of
rags in a suitable manner. (00267a)

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.7 FUEL TANK: XR MODELS

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

6.38 MAIN FUSE

See

Figure 4-58

. Unplug harness connector [87B] from

IAC connector [87A] (1).

NOTE

Screws (2) MUST be heated to soften the thread sealant and
avoid breakage during removal. Use ONLY HEAT GUN (Part
No. HD-25070) to heat the screws. NEVER use an open flame.

Using a six-point socket (not a Torx wrench), remove two
screws (2) in the following order:

Heat fastener nearest to throttle bracket for two
minutes using HEAT GUN (Part No. HD-25070).
Remove screw.

Heat remaining screw for one minute and remove.

See

Figure 4-59

. Grasp IAC and rotate counterclockwise

until IAC mounting tab (1) clears throttle cable bracket (2).

With a gentle twisting motion, pull IAC straight out of
induction module body.

sm04969

IAC Connector [87A]

Screw (2)

IAC

Throttle cable bracket

Figure 4-58. IAC Removal/Installation (XR Models)

HOME

4-40 2009 Sportster Service: Fuel System

sm04970

IAC mounting tab (2) (rotated 45 degrees)

Throttle cable bracket

Figure 4-59. Removing/Installing IAC (XR Models)

INSTALLATION: XR MODELS

See

Figure 4-57

. If re-using IAC (1), inspect o-ring (2) for

cuts, tears or signs of deterioration. If necessary, replace
with new o-ring.

Clean all locking agent from the threads of the attachment
screws and holes. Blow debris from screw holes using
low-pressure compressed air.

Apply a thin coat of clean engine oil to o-ring.

Note orientation and position of IAC, shown in

Figure 4-58

Rotate IAC approximately 45 degrees counterclockwise
from this position (see

Figure 4-59

.) so IAC mounting tab

will clear throttle cable bracket (4) when IAC is installed.

With a gentle twisting motion, insert IAC into induction
module.

Rotate IAC so that harness connector points straight down
and mounting tab is underneath tab on throttle cable
bracket.

See

Figure 4-58

. Apply a drop of Loctite Threadlocker and

Sealant 243 (blue) the threads of each screw (2).

See

Figure 4-58

. Install two screws (2). Using a six-point

socket (not a TORX wrench), tighten to 60 in-lbs (6.8 Nm).

Plug harness connector [87B] into IAC connector [87A]
(1).

10. Connect fuel hose to fuel pump module. Fill fuel tank with

gasoline. See

4.7 FUEL TANK: XR MODELS

11. Plug in main fuse and close left side cover. See

6.38 MAIN

FUSE

12. Turn on ignition switch and start vehicle. Carefully check

for leaks around fuel hose fitting.

13. Road test vehicle.

HOME

2009 Sportster Service: Fuel System 4-41

4.13

TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR

GENERAL

See

Figure 4-60

. The Temperature Manifold Absolute Pressure

(TMAP) sensor (1) performs the dual functions of monitoring
air temperature and air pressure in the intake manifold.

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the TMAP sensor.

sm01622

TMAP sensor

Screw (2) (XL only)

Screw (XR only)

Induction module/intake manifold: XL models

Induction module: XR models

Figure 4-60. TMAP Sensor Location (Induction Module

Removed From Vehicle for Clarity)

REMOVAL: XL MODELS

NOTE

It is not necessary to remove the fuel tank from the vehicle in
order to replace the TMAP sensor.

HOME

4-42 2009 Sportster Service: Fuel System

To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)

Unplug main fuse. See

6.38 MAIN FUSE

Remove air cleaner cover, air filter element and backing
plate assembly. See

4.4 AIR CLEANER: XL MODELS

Remove fuel rail and fuel injectors. See

4.17 FUEL

INJECTORS

. This will allow access to the two screws that

secure the induction module to the intake manifold.

See

Figure 4-60

. Remove two screws (2) and separate

induction module from intake manifold. See

4.10 INDUC-

TION MODULE: XL MODELS

See

Figure 4-61

. Pull induction module away from intake

manifold far enough so that TMAP sensor retaining bracket
(1) clears TMAP sensor body (2).

Unplug harness connector [80B] from TMAP connector
[80A] (3).

Grasp TMAP sensor and with a gentle twisting motion,
pull sensor straight up out of intake manifold body.

sm01623

TMAP sensor retaining bracket

TMAP sensor

Sensor connector [80A]

O-ring

Figure 4-61.TMAP Sensor Removal/Installation (Induction

Module Removed From Vehicle for Clarity)

INSTALLATION: XL MODELS

See

Figure 4-62

. If re-using TMAP sensor (1), inspect o-

ring (2) in groove of sensor for cuts, tears or signs of
deterioration. Install new o-ring if necessary.

Apply a thin coat of clean engine oil to TMAP sensor o-
ring.

See

Figure 4-61

. With a gentle twisting motion, insert

sensor (2) into intake manifold with connector [80A] (3)
facing rear cylinder head.

Plug harness connector [80B] into TMAP sensor.

Examine o-ring (4) between induction module and intake
manifold for cuts, tears or signs of deterioration. Install
new o-ring if necessary. Make certain o-ring is fully seated
in its grove in induction module body.

See

Figure 4-60

. Mate induction module to intake manifold

and secure with two screws (2) Tighten to 35 in-lbs (4.0
Nm).

Install fuel injectors and fuel rail. See

4.17 FUEL

INJECTORS

Install air cleaner backing plate assembly, air filter element
and air cleaner cover. See

4.4 AIR CLEANER: XL

MODELS

To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Connect fuel hose to fuel pump module. Fill fuel tank and
carefully check for leaks around fuel pump module. See

4.6 FUEL TANK: XL MODELS, Reconnecting Fuel Hose
and Filling Fuel Tank

10. Install main fuse and close left side cover. See

6.38 MAIN

FUSE

HOME

2009 Sportster Service: Fuel System 4-43

sm01624

TMAP sensor

O-ring

Figure 4-62. TMAP Sensor

REMOVAL: XR MODELS

NOTE

It is not necessary to remove the fuel tank, airbox or induction
module from the vehicle in order to replace the TMAP sensor.

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

6.38 MAIN FUSE

NOTE

See

Figure 4-64

.TMAP sensor harness and TP sensor harness

are attached to inside of induction module cover (1). It is not
necessary to remove the retainer securing these harnesses to
the induction module cover in order to access TMAP sensor.

See

Figure 4-63

. Remove socket head bolts (3), fastener

(1) and fastener (2).

See

Figure 4-64

. Carefully rotate induction module cover

(1) out of the way.

Unplug TMAP sensor harness connector [80B] (2).
Remove screw (4).

Grasp TMAP sensor (3) and with a gentle twisting motion,
pull sensor straight up out of induction module body.

sm05419

Fastener, wire form

Fastener, to induction module

Socket head bolts (2)

Figure 4-63. Induction Module Cover

sm04966

Induction module cover

Sensor harness connector [80B]

TMAP sensor [80A]

Screw

Figure 4-64. TMAP Sensor: XR Models (airbox removed

for clarity of photo)

INSTALLATION: XR MODELS

See

Figure 4-62

. If re-using TMAP sensor (1), inspect o-

ring (2) for cuts, tears or signs of deterioration. If neces-
sary, replace with new o-ring.

Apply a thin coat of clean engine oil to TMAP sensor o-
ring.

See

Figure 4-64

. With a gentle twisting motion, insert

sensor (3) into induction module with connector [80A]
pointing down. Secure sensor to induction module with
screw (4). Tighten to 60 in-lbs (6.8 Nm).

Plug sensor harness connector [80B] (2) into TMAP
sensor.

NOTE

Install all fasteners finger tight before final tightening any.

HOME

4-44 2009 Sportster Service: Fuel System

4.14

OXYGEN SENSOR

GENERAL

NOTE

Photographs of XL models will be used throughout this process.
Although the exact location of the O2 sensors vary slightly
between XL models and XR models, replacement procedures
are essentially the same. For ease of installation, note harness
routing prior to removal.

See

Figure 4-65

. The oxygen (O2) sensors are installed in

threaded bosses on the inboard side of front and rear exhaust
pipes.

NOTE

Both Oxygen sensors are identical. However, if they will be
reused, it is best to mark them FRONT or REAR and return
each to the exhaust pipe in which it was originally mounted.

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the O2 sensors.

sm01642

Front oxygen sensor

Rear oxygen sensor

Figure 4-65. Oxygen Sensor Locations, typical (XL model

shown)

REMOVAL

TOOL NAME

PART NUMBER

OXYGEN SENSOR SOCKET

HD-48262

OXYGEN SENSOR SOCKET

HD-48647

Unplug sensor connector:

Front O2 sensor: see

Figure 4-66

. Remove frame

clip (2). Unplug sensor connector [138A] (3) from
wiring harness connector [138B].

Rear O2 sensor: see

Figure 4-67

. Disengage con-

nector [137] (2) from mounting tab. Unplug connector
[137A] from wiring harness connector [137B].

Using the appropriate tool, remove sensor from mounting
boss on exhaust pipe. If reusing sensor, be careful not to
damage sensor harness.

XL Models: OXYGEN SENSOR SOCKET (Part
No. HD-48262).

XR Models: OXYGEN SENSOR SOCKET (Part
No. HD-48647).

sm01643

Front oxygen sensor

Frame clip

Sensor connector [138]

Figure 4-66. Front Oxygen Sensor and Connector, typical

(XL model shown)

HOME

4-46 2009 Sportster Service: Fuel System

sm01644

Rear oxygen sensor

Sensor connector [137]

Figure 4-67. Rear Oxygen Sensor and Connector, typical

(XL model shown)

INSTALLATION

NOTES

•

Do not install sensors that have been dropped or impacted
by other components. Damage to the sensor element may

have occurred. Replacement sensor assemblies have
threads coated with anti-seize lubricant and new seal rings.

•

Apply a thin coat of anti-seize to threads of each oxygen
sensor prior to installing in header. Do not use any other
grease or sealant product on sensor threads. The electrical
connector must also be clean and free of any dielectric
grease.

If sensor is being reused, install new seal ring and coat
sensor threads with anti-seize.

Install sensor into threaded boss on exhaust pipe and
tighten to 29-44 ft-lbs (39.3-59.7 Nm).

Route sensor harness to mating connector and connect:

Front O2 sensor: see

Figure 4-66

. Plug sensor

connector [138A] (3) into wiring harness connector
[138B]. Install frame clip (2) over sensor harness,
clutch cable and wiring harness on left frame down-
tube.

Rear O2 sensor: see

Figure 4-67

. Plug connector

[137A] (2) into wiring harness connector [137B].
Engage connector assembly onto mounting tab on
bracket.

NOTE

Route rear O2 sensor harness in a loop away from exhaust
system, toward left side of vehicle (as shown in the photo) to
avoid contact with exhaust port or exhaust pipe.

HOME

2009 Sportster Service: Fuel System 4-47

4.15

EXHAUST SYSTEM: XL MODELS

GENERAL

TOOL NAME

PART NUMBER

SNAP-ON WRENCH

PFSX916

To facilitate removing exhaust pipe header nuts, use SNAP-
ON WRENCH (Part No. PFSX916).

sm02198

23.

12.

Screw

Heat shield, rear exhaust pipe

Muffler, front

24.

13.

Muffler, rear

Engine sprocket cover

Worm drive clamp (5)

14.

25.

Muffler heat shield (2) (Cali-
fornia, HDI, England only)

Exhaust pipe, front

Screw

26.

Washer

Exhaust pipe, rear

15.

27.

Worm drive clamp (4)

Muffler interconnect bracket

Front O2 sensor assembly

28.

16.

Rear O2 sensor assembly

Flanged bolt (4)

Torca muffler clamp assembly
(2)

29.

17.

Seal ring (2)

Screw (3)

18.

Exhaust port gasket (2)

30.

Washer (3)

O2 sensor connectors (2):
[137], [138]

19.

Muffler interconnect gasket (2)

Exhaust gasket retaining ring
(2)

31. Heat shield, rear exhaust pipe

(mid-control vehicles only)

20. Exhaust pipe clamp

21.

Exhaust pipe flange (2)

Exhaust pipe clamp bracket

22.

10.

Acorn nut

Nut (4)

11. Heat shield, front exhaust

pipe

Figure 4-68. Exhaust System, All XL Models

HOME

4-48 2009 Sportster Service: Fuel System

REMOVAL

Mufflers and Exhaust Pipes

NOTE

See

Figure 4-69

. Vehicles with mid controls are equipped with

an extra heat shield (2) on the rear exhaust pipe.

See

Figure 4-68

. Remove heat shields:

Vehicles with mid controls: remove worm drive
clamps (13) from heat shield (12) completely. Remove
bottom heat shield.

All vehicles: open worm drive clamps (13) and
remove exhaust pipe heat shields (11, 12).

California, HDI and England models: open worm
drive clamps (15) and remove muffler heat shields
(14).

Unplug O2 sensor connectors (30). Front connector [138]
is mounted on left front frame downtube. Rear connector
[137] is attached to H-bracket behind engine on right side
of vehicle.

Remove nuts (10) from front and rear cylinder head
exhaust studs.

Remove flanged bolts (16) securing front and rear mufflers
(1, 2) to muffler interconnect bracket (5).

Loosen Torca muffler clamp assemblies (6) on front and
rear mufflers. Remove mufflers. Discard muffler intercon-
nect gaskets (19).

Remove and discard Torca clamp assemblies; they are
one time usage only.

NOTE

New Torca muffler clamps have eliminated the need for silicone
or graphite tape during assembly. To ensure sealing integrity
of muffler clamps and prevent the possibility of leakage, Harley-
Davidson recommends that torca muffler clamp assemblies
be discarded and replaced each time they are removed.

Remove nut (22) and screw (23) from exhaust pipe clamp
(20). Separate exhaust pipe clamp from clamp bracket
(21).

Remove front and rear exhaust pipes (3, 4). Slide exhaust
pipe clamp off rear exhaust pipe.

Remove exhaust port gasket (7), retaining ring (8) and
exhaust pipe flange (9) from each exhaust pipe. Discard
gasket.

10. Remove O2 sensor assemblies (27, 28) from front and

rear exhaust pipes. Discard gaskets (29). See

4.14 OXYGEN SENSOR

sm04380

Top heat shield

Bottom heat shield

Upper worm drive clamp

Lower worm drive clamp

Figure 4-69. Rear Exhaust Pipe Heat Shields:Vehicles with

Mid Controls

Muffler Interconnect Bracket

See

Figure 4-70

. Remove screw (6), washer (5) and

exhaust pipe clamp bracket (4). Remove two screws (2,
3). Remove sprocket cover (1).

See

Figure 4-71

. Remove rear brake rod (1) at bell crank

(2).

See

Figure 4-68

. Remove three screws (17) and washers

(18) securing muffler interconnect bracket (5) to engine
crankcase. Remove muffler interconnect bracket.

sm02202

Sprocket cover

Screw

Exhaust pipe clamp bracket

Washer

Screw

Figure 4-70. Sprocket Cover

HOME

2009 Sportster Service: Fuel System 4-49

sm02199

Rear brake rod

Bell crank

Rear brake master cylinder assembly

Rear brake pedal

Frame

Figure 4-71. Rear Brake Linkage

INSTALLATION

TOOL NAME

PART NUMBER

SNAP-ON SWIVEL BALL SOCKET
EXTENSION

PFSX916

Muffler Interconnect Bracket

See

Figure 4-68

. Install muffler interconnect bracket (5)

to engine case with three screws (17) and washers (18).
Tighten to 30-33 ft-lbs (40.7-44.8 Nm).

See

Figure 4-71

. Apply two drops of LOCTITE 243 (Part.

No. 99642-97) to rear brake rod ball stud screw. Attach
rear brake rod (1) to bell crank (2). Tighten screw to 120-
180 in-lbs (13.6-20.4 Nm).

See

Figure 4-70

. Install sprocket cover (1). Secure with

two screws (2, 3). Note that long screw goes in top hole,
short screw in bottom hole. Do not tighten screws at this
time.

Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).

Exhaust Pipes and Mufflers

NOTES

•

To facilitate installing exhaust pipe header nuts, use
SNAP-ON SWIVEL BALL SOCKET EXTENSION (Part
No. PFSX916).

•

If the O2 sensors are being reused, apply a thin coat of
anti-seize to threads of each sensor prior to installing in

header. Do not use any other grease or sealant product
on sensor threads. The electrical connector must also be
clean and free of any dielectric grease.

See

Figure 4-68

. If the front and rear O2 sensor assem-

blies (27, 28) are being reused, install new seal rings (29)
onto each sensor. Apply a thin coat of anti-seize to the
sensor threads.

Install sensor assemblies into front and rear exhaust pipes.
Tighten to 29-44 ft-lbs (39.3-59.7 Nm). See

4.14 OXYGEN

SENSOR

Place exhaust pipe flange (9), exhaust gasket retaining
ring (8) and new exhaust port gasket (7) over front end of
each exhaust pipe (3, 4). Position flange so that inside
counterbore faces cylinder head exhaust port.

Position front ends of front and rear exhaust pipes into
front and rear cylinder heads, respectively. Position holes
in flanges over mounting studs and loosely install nuts
(10). Do not tighten nuts at this time.

Install exhaust pipe clamp (20) on rear exhaust pipe (4)
with square hole facing down. Assemble exhaust pipe
clamp to exhaust pipe clamp bracket (21) with screw (23)
and acorn nut (22). Make sure bracket fits between ends
of clamp. Do not tighten at this time.

Install new muffler interconnect gaskets (19) in intercon-
nect mating holes in mufflers (1, 2).

Place new Torca clamp assemblies (6) over slotted end
of each muffler. Install each muffler onto the end of its
respective exhaust pipe.

Rotate both mufflers until their mounting bosses line up
with holes in muffler interconnect bracket. Carefully mate
each muffler with exhaust port in interconnect bracket.
Loosely install flanged bolts (16). Do not tighten at this
time.

Tighten exhaust system fasteners in the following
sequence:

Tighten four flanged bolts securing mufflers to inter-
connect bracket to 15-19 ft-lbs (20.4-25.8 Nm).

Tighten four nuts at cylinder head exhaust studs to
96-120 in-lbs (10.9-13.6 Nm).

Tighten two Torca clamps to 38-43 ft-lbs (51.6-58.4
Nm).

Tighten rear exhaust pipe clamp nut (22) to 15-19 ft-
lbs (20.4-25.8 Nm).

10. Plug in O2 sensor connectors (30). Front connector [138]

is mounted on left front frame downtube. Rear connector
[137] is attached to H-bracket behind engine on right side
of vehicle. See

4.14 OXYGEN SENSOR

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4-50 2009 Sportster Service: Fuel System

Harley Davidson Sportster Models 2009. Service Repair Manual - page 33