Harley Davidson Sportster Models 2009. Service Repair Manual - page 56

E.21

TSM/TSSM: PASSWORD LEARN

GENERAL

If the ECM or TSM/TSSM is faulty, follow the instructions in
the Service Manual for ECM or TSM/TSSM replacement. Then,
to determine if password learn is necessary, refer to

Table E-23

Table E-23. Password Learn

IS PASSWORD LEARN

NECESSARY?

DEVICE REPLACED

Yes

ECM

No *

TSM

Yes

TSSM

* If a TSM has been replaced by a TSSM, or a TSSM has
been replaced by a TSM, password learn is necessary.

PASSWORD LEARNING

To perform password learning procedure, refer to

Table E-24

When finished, continue with all instructions under

E.3 VEHICLE DELIVERY

Always perform all appropriate instructions under

E.3 VEHICLE

DELIVERY

after TSM/TSSM replacement or removal.

NOTE

Do not forget to enter a Personal Identification Number (PIN)
for TSSM vehicles. If a code is not assigned and the key fob
is lost or damaged while the vehicle is armed, the TSSM must
be replaced.

Table E-24. Setting TSM/TSSM and ECM Password

NOTES

CONFIRMATION

ACTION

NO.

With ignition turned off, check engine
lamp and security lamp will be off.

Ignition must be turned off for at least
15 seconds.

Install new TSM/TSSM or ECM. Per-
form all steps under

E.3 VEHICLE

DELIVERY

Set engine stop switch to RUN.

TSM/TSSM enables starter
relay.

Verify check engine lamp and security
lamp illuminate and then turn off.

Turn ignition switch ON.

Password has not been
learned. ECM sets DTC
P1009.

Engine starts and stalls. Check engine
lamp illuminates and stays on.

Attempt normal start one time.

ECM enters Password
Learning mode for ten
minutes. Do not cycle ignition
switch or interrupt vehicle
power or Password Learn will
be unsuccessful.

Security lamp illuminates.

Wait ten seconds. security lamp will
illuminate and stay on.

This takes ten minutes.

Wait until security lamp turns off.

ECM must not be allowed to
shutdown.

Quickly (within one second) turn igni-
tion switch OFF-ON.

This takes ten minutes.

Wait until security lamp turns off.

ECM must not be allowed to
shutdown.

Quickly (within one second) turn igni-
tion switch OFF-ON.

This takes ten minutes.

Wait until security lamp turns off.

ECM must not be allowed to
shutdown.

Quickly (within one second) turn igni-
tion switch OFF-ON.

Turn ignition switch OFF. Wait 15
seconds before turning ignition switch
ON. Turn ignition switch ON and start
engine to confirm successful Password
Learn procedure. Clear DTCs.

Perform all steps under

E.3 VEHICLE

DELIVERY

HOME

E-64 2009 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea)

E.22

TSSM MAINTENANCE

GENERAL

The TSSM system uses batteries in the key fob and siren.
These are the only parts requiring periodic maintenance.

KEY FOB

Schedule

Replace the key fob battery every 2 years.

Battery Replacement

See

Figure E-29

. Open the key fob case.

Place a thin blade between the 2 halves of the case.

Slowly twist the blade.

Replace battery (1).

Remove the original battery.

Install a new battery with the positive (+) side down.
Use a Panasonic® 2032 or equivalent.

Align case and circuit board (3) as shown. Snap case
halves together.

While standing next to the motorcycle, press and hold the
key fob button for 10-15 seconds until the security system
responds with two turn signal flashes/siren chirps.

ed030114

Battery

Battery contact

Circuit board

Figure E-29. Open Key Fob: TSSM

ed03015

Figure E-30. Key Fob Assembly: TSSM

SIREN (IF INSTALLED)

Schedule

The siren's internal 9 volt battery is rechargeable and does not
need to be replaced on a regular basis. Battery life under
normal conditions is approximately three to six years.

NOTES

•

. Early style siren will

work with both TSSM and HFSM. Late style siren will only
work with HFSM.

•

The internal siren battery may not charge if the vehicle's
battery is less than 12.5 volts.

Battery Replacement: Early Style Siren

Disarm system and remove siren.

See

Figure E-31

. Remove battery cover.

Place the siren module on a flat and sturdy table with
the potted section (area with epoxy covering circuit
board) facing up and towards you.

Position a knife blade at a 45 degree angle to the long
side of the siren case. Insert the knife blade between
the siren case and battery cover at one of the two
accessible corners of the battery cover. Keep the
blade slightly higher towards the battery cover as this
helps keep the blade away from the battery seal.

Slowly twist the blade towards the battery cover and
the cover will pop off.

NOTES

•

For protection against corrosion, battery terminals and
battery clip are covered with a special grease. Do not wipe
away this substance. Apply all available existing grease
to terminals on new battery.

•

Only a 9 volt nickel metal hydride battery should be used
in the siren.

HOME

2009 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea) E-65

Replace battery by removing old battery from polarized
battery clip. Install a new 9 volt nickel metal hydride bat-
tery.

Reinstall battery cover.

Carefully replace the rubber seal.

Align battery cover with case placing round corners
on cover away from connector [142A]. Snap cover
into place.

Install siren and check operation. If siren is working prop-
erly, it will respond with two chirps after receiving the arm
command.

Battery Replacement: Late Style Siren

Disarm system and remove siren.

See

Figure E-32

. With a small screwdriver or pick, push

the catches (1) in through the two slots (2) in the end of
the siren to release the battery cover (3).

NOTES

•

Only a 9 volt nickel metal hydride battery should be used
in the siren.

Replace battery (4) by removing old battery from polarized
battery clip.

Recharge and re-install or install a new 9 volt nickel metal
hydride battery.

Reinstall battery cover (3).

Carefully replace the rubber seal (5) on the cover.

Align battery cover with case placing round corners
on cover away from connector [142A] (6).

Snap cover into place.

Install siren and check operation. If siren is working prop-
erly, it will respond with two chirps after receiving the arm
command.

ed03016

Cover

Battery

Connector [142A]

Figure E-31. Battery Compartment (Early Style Siren)

ed02958

Catch

Slot

Cover

9 Volt battery

Rubber seal

Connector [142A]

Figure E-32. Siren Battery Compartment (Late Style Siren)

HOME

E-66 2009 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea)

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

4.16 DTC P0107, P0108, P0112, P0113, Diagnostics

VACUUM PUMP

HD-23738

A.18 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

ROBINAIR HEAT GUN

HD-25070

4.9 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics

SPARK TESTER

HD-26792

4.15 MISFIRE AT IDLE OR UNDER LOAD, Diagnostics

SPARK TESTER

HD-26792

4.9 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics

FUEL INJECTOR TEST LAMP

HD-34730-2C

4.27 DTC P1351, P1352, P1354, P1355, Diagnostics

FUEL INJECTOR TEST LAMP

HD-34730-2C

A.14 METRI-PACK TERMINALS, Metri-Pack Terminal
Crimps

PACKARD TERMINAL CRIMP TOOL

HD-38125-6

A.6 DEUTSCH MINI-TERMINAL CRIMPS, Deutsch Mini
Terminal Crimps

PACKARD TERMINAL CRIMPER

HD-38125-7

A.14 METRI-PACK TERMINALS, Metri-Pack Terminal
Crimps

PACKARD TERMINAL CRIMPER

HD-38125-7

A.14 METRI-PACK TERMINALS, Metri-Pack Terminal
Crimps

PACKARD CRIMPING TOOL

HD-38125-8

A.18 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

PACKARD CRIMPING TOOL

HD-38125-8

A.5 DEUTSCH STANDARD TERMINALS, Deutsch
Standard Terminal Crimps

DEUTSCH TERMINAL CRIMP TOOL

HD-39965-A

A.18 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

ULTRA TORCH UT-100

HD-39969

A.18 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

HEAT SHIELD ATTACHMENT

HD-41183

1.2 STARTING SYSTEM DIAGNOSIS, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

2.4 SPEEDOMETER/TACHOMETER, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

3.15 TSM/HFSM: TURN SIGNAL ERRORS AND
DTCS, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

3.16 DTC B1131, B1132 (HFSM ONLY), Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

3.18 DTCS B1135, B1136, B1141, AND B1142, DTC
B1141 Ignition Switch Open/Low

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.9 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.9 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.10 NO ECM POWER, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.12 FUEL SYSTEM ELECTRICAL TEST, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.14 IDLE AIR CONTROL, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.15 MISFIRE AT IDLE OR UNDER LOAD, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.16 DTC P0107, P0108, P0112, P0113, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.16 DTC P0107, P0108, P0112, P0113, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.17 DTC P0117, P0118, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.18 DTC P0122, P0123, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.20 DTC P0261, P0262, P0263, P0264, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.21 DTC P0373, P0374, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.25 DTC P0661, P0662, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.27 DTC P1351, P1352, P1354, P1355, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

4.27 DTC P1351, P1352, P1354, P1355, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

OOLS

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

E.13 TURN SIGNAL ERRORS: B1121, B1122,
B1141, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

E.15 DTC B1131, B1132, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

2.6 INDICATOR LAMPS, Diagnostics

HARNESS CONNECTOR TEST KIT

HD-41404-B

A.4 DEUSCH ELECTRICAL CONNECTORS, Deutsch
Connector Repair

DEUTSCH CONNECTOR SERVICE KIT

HD-41475

A.4 DEUSCH ELECTRICAL CONNECTORS, Deutsch
Connector Repair

FLAT BLADE L-HOOK

HD-41475-100

A.1 AMP MULTILOCK CONNECTORS, AMP Multilock
Connector Repair

AMP MULTILOCK CRIMPER

HD-41609

1.2 STARTING SYSTEM DIAGNOSIS, Diagnostics

BREAKOUT BOX

HD-42682

2.2 INITIAL DIAGNOSTIC CHECK: ODOMETER, Initial
Diagnostics

BREAKOUT BOX

HD-42682

2.4 SPEEDOMETER/TACHOMETER, Diagnostics

BREAKOUT BOX

HD-42682

2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, General

BREAKOUT BOX

HD-42682

2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, Speedometer: XL only

BREAKOUT BOX

HD-42682

2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, Speedometer: XL only

BREAKOUT BOX

HD-42682

2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, Tachometer

BREAKOUT BOX

HD-42682

2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, Tachometer

BREAKOUT BOX

HD-42682

2.7 DTC B1004, B1005, Diagnostics

BREAKOUT BOX

HD-42682

2.9 DTC B1008, Diagnostics

BREAKOUT BOX

HD-42682

2.10 DTC U1016, U1255, Diagnostics

BREAKOUT BOX

HD-42682

2.11 DTC U1064, U1255, Diagnostics

BREAKOUT BOX

HD-42682

3.3 H-DSSS ACTUATION, Power Disruption and Config-
uring

BREAKOUT BOX

HD-42682

3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM, Initial
Diagnostics

BREAKOUT BOX

HD-42682

3.12 BREAKOUT BOX: TSM/HFSM, General

BREAKOUT BOX

HD-42682

3.16 DTC B1131, B1132 (HFSM ONLY), Diagnostics

BREAKOUT BOX

HD-42682

3.17 DTC B1134, Diagnostics

BREAKOUT BOX

HD-42682

3.20 DTC B1154, B1155, Diagnostics

BREAKOUT BOX

HD-42682

4.5 INITIAL DIAGNOSTIC CHECK: EFI, Initial Dia-
gnostics

BREAKOUT BOX

HD-42682

4.29 DTC U1064, U1255, Diagnostics

BREAKOUT BOX

HD-42682

E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM, Initial
Diagnostics

BREAKOUT BOX

HD-42682

E.11 BREAKOUT BOX: TSM/TSSM, General

BREAKOUT BOX

HD-42682

E.15 DTC B1131, B1132, Diagnostics

BREAKOUT BOX

HD-42682

E.16 DTC B1134, Diagnostics

BREAKOUT BOX

HD-42682

4.30 DTC U1097, U1255, Diagnostics

BREAKOUT BOX

HD-42682

II TOOLS

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

A.7 DEUTSCH SOLID BARREL TERMINALS, Deutsch
Solid Barrel Terminal Crimps

ELECTRICAL CRIMPER TOOL

HD-42879

3.21 DTC U1016, U1255, Diagnostics

BREAKOUT BOX

HD-43876

4.7 BREAKOUT BOX: EFI, General

BREAKOUT BOX

HD-43876

4.9 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics

BREAKOUT BOX

HD-43876

4.10 NO ECM POWER, Diagnostics

BREAKOUT BOX

HD-43876

4.12 FUEL SYSTEM ELECTRICAL TEST, Diagnostics

BREAKOUT BOX

HD-43876

4.13 SYSTEM RELAY CHECK, Diagnostics

BREAKOUT BOX

HD-43876

4.14 IDLE AIR CONTROL, Diagnostics

BREAKOUT BOX

HD-43876

4.15 MISFIRE AT IDLE OR UNDER LOAD, Diagnostics

BREAKOUT BOX

HD-43876

4.16 DTC P0107, P0108, P0112, P0113, Diagnostics

BREAKOUT BOX

HD-43876

4.16 DTC P0107, P0108, P0112, P0113, Diagnostics

BREAKOUT BOX

HD-43876

4.17 DTC P0117, P0118, Diagnostics

BREAKOUT BOX

HD-43876

4.18 DTC P0122, P0123, Diagnostics

BREAKOUT BOX

HD-43876

4.19 DTC P0131, P0132, P0134, P0151, P0152,
P0154, Diagnostics

BREAKOUT BOX

HD-43876

4.20 DTC P0261, P0262, P0263, P0264, Diagnostics

BREAKOUT BOX

HD-43876

4.22 DTC P0501, P0502, Diagnostics

BREAKOUT BOX

HD-43876

4.25 DTC P0661, P0662, Diagnostics

BREAKOUT BOX

HD-43876

4.26 DTC P1009, P1010, Diagnostics

BREAKOUT BOX

HD-43876

4.27 DTC P1351, P1352, P1354, P1355, Diagnostics

BREAKOUT BOX

HD-43876

4.30 DTC U1097, U1255, Diagnostics

BREAKOUT BOX

HD-43876

E.19 DTC U1016, U1255, Diagnostics

BREAKOUT BOX

HD-43876

4.9 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics

IGNITION COIL CIRCUIT TEST ADAPTER

HD-44687

4.27 DTC P1351, P1352, P1354, P1355, Diagnostics

IGNITION COIL CIRCUIT TEST ADAPTER

HD-44687

A.17 PACKARD MICRO-64 CONNECTORS, Packard
Micro-64 Connector Repair

PACKARD MICRO-64 TERMINAL
REMOVER

HD-45928

A.17 PACKARD MICRO-64 CONNECTORS, Packard
Micro-64 Connector Repair

PACKARD MICRO-64 TERMINAL
CRIMPER

HD-45929

2.2 INITIAL DIAGNOSTIC CHECK: ODOMETER, Initial
Diagnostics

INSTRUMENT HARNESS ADAPTERS

HD-46601

2.4 SPEEDOMETER/TACHOMETER, Diagnostics

INSTRUMENT HARNESS ADAPTERS

HD-46601

2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, General

INSTRUMENT HARNESS ADAPTERS

HD-46601

2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, Speedometer: XL only

INSTRUMENT HARNESS ADAPTERS

HD-46601

2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, Speedometer: XL only

INSTRUMENT HARNESS ADAPTERS

HD-46601

2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, Tachometer

INSTRUMENT HARNESS ADAPTERS

HD-46601

2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, Tachometer

INSTRUMENT HARNESS ADAPTERS

HD-46601

2.7 DTC B1004, B1005, Diagnostics

INSTRUMENT HARNESS ADAPTERS

HD-46601

TOOLS III

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

2.9 DTC B1008, Diagnostics

INSTRUMENT HARNESS ADAPTERS

HD-46601

2.10 DTC U1016, U1255, Diagnostics

INSTRUMENT HARNESS ADAPTERS

HD-46601

2.11 DTC U1064, U1255, Diagnostics

INSTRUMENT HARNESS ADAPTERS

HD-46601

3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM, Initial
Diagnostics

INSTRUMENT HARNESS ADAPTERS

HD-46601

4.5 INITIAL DIAGNOSTIC CHECK: EFI, Initial Dia-
gnostics

INSTRUMENT HARNESS ADAPTERS

HD-46601

4.29 DTC U1064, U1255, Diagnostics

INSTRUMENT HARNESS ADAPTER

HD-46601

4.30 DTC U1097, U1255, Diagnostics

INSTRUMENT HARNESS ADAPTER

HD-46601

E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM, Initial
Diagnostics

INSTRUMENT HARNESS ADAPTERS

HD-46601

1.7 CHARGING SYSTEM, Troubleshooting

ELECTRICAL SYSTEM TESTER

HD-48053

A.15 MOLEX CONNECTORS, Molex Connector Repair

MOLEX ELECTRICAL CONNECTOR TER-
MINAL REMOVER

HD-48114

2.10 DTC U1016, U1255, Diagnostics

ECM BREAKOUT BOX

HD-48637

2.1 CHECKING FOR DIAGNOSTIC TROUBLE
CODES, Code Types

DIGITAL TECHNICIAN II

HD-48650

3.2 HARLEY-DAVIDSON SMART SECURITY
SYSTEM, HFSM Features

DIGITAL TECHNICIAN II

HD-48650

3.7 SERVICE/EMERGENCY FUNCTIONS, Service Mode

DIGITAL TECHNICIAN II

HD-48650

3.23 TSM/HFSM: PASSWORD LEARN, Password
Learning

DIGITAL TECHNICIAN II

HD-48650

4.14 IDLE AIR CONTROL, General

DIGITAL TECHNICIAN II

HD-48650

4.19 DTC P0131, P0132, P0134, P0151, P0152,
P0154, Diagnostics

DIGITAL TECHNICIAN II

HD-48650

4.24 DTC P0603, P0605, General

DIGITAL TECHNICIAN II

HD-48650

E.8 DIAGNOSTIC TROUBLE CODES (DTC), Code
Types

DIGITAL TECHNICIAN II

HD-48650

4.9 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics

ELECTRICAL SYSTEM ANALYZER

MCR-101 HD

A.12 630 METRI-PACK CONNECTORS, 630 Metri-Pack
Connector Repair

SNAP-ON PICK

SNAP-ON TT600-3

IV TOOLS

150 Metri-Pack Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18

280 Metri-Pack Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20

480 Metri-Pack Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22

630 Metri-Pack Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23

Active Intake Solenoid (HDI Models Only). . . . . . . . . . 4-105
AMP Multilock Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Bank Angle Sensor (HDJ/Korea). . . . . . . . . . . . . . . . . . . E-2
Bank Angle Sensor Description. . . . . . . . . . . . . . . . . . . . . 4-3
Bank Angle Sensor Function. . . . . . . . . . . . . . . . . . . . . . . 3-1
Battery Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Conductance Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Voltmeter Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Bus ER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Charging System Testing

Current Voltage Output Test: Using HD-48053. . . . . 1-25
Current Voltage Output Test: Using Load Tester. . . . 1-25
Milliampere Draw Test. . . . . . . . . . . . . . . . . . . . . . . 1-24
Total Current Draw Test. . . . . . . . . . . . . . . . . . . . . . 1-24

Check Engine Lamp EFI. . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Check Engine Lamp Functionality. . . . . . . . . . . . . . . . . . . 2-1
CKP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Connectors

Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Conversions

Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . 4-3

Delphi Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Deutsch 1-Place Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Deutsch Connector

Crimping Mini Terminals. . . . . . . . . . . . . . . . . . . . . . A-14
Crimping Solid Barrel Terminals. . . . . . . . . . . . . . . . A-15
Crimping Standard Terminals. . . . . . . . . . . . . . . . . . A-13
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Diagnostic Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Diagnostic Trouble Code Types. . . . . . . . . . . . . . . . . . . . . 2-3

Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Historic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Retreiving Diagnostic Trouble Codes. . . . . . . . . . . . . 2-3

DTC B0563: Battery Voltage High. . . . . . . . . . . . . . . . . . 3-31
DTC B0563 Battery Voltage High (HDJ/Korea). . . . . . . . E-46
DTC B1004 Fuel Level Sending Unit Low. . . . . . . . . . . . 2-26
DTC B1005 Fuel Level Sending Unit High/Open. . . . . . . 2-26
DTC B1006 Accessory Line Overvoltage. . . . . . . . . . . . 2-30

DTC B1007 Ignition Line Overvoltage. . . . . . . . . . . . . . . 2-30
DTC B1008 Trip Odometer Reset Switch Closed. . . . . . 2-32
DTC B1121, B1122, B1141 Turn Signals Will Not Flash, 4-Way
Flashers Inoperable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
DTC B1123 Left Turn Signal Short-to-Ground. . . . . . . . . 3-32
DTC B1124 Right Turn Signal Short-to-Ground. . . . . . . 3-32
DTC B1125 Left Turn Signal Short-to-Voltage. . . . . . . . . 3-32
DTC B1126 Right Turn Signal Short-to-Voltage. . . . . . . 3-32
DTC B1131 Alarm Output Low. . . . . . . . . . . . . . . . . . . . 3-48
DTC B1131 Alarm Output Low (HDJ/Korea). . . . . . . . . . E-47
DTC B1132 Alarm Output High. . . . . . . . . . . . . . . . . . . . 3-48
DTC B1132 Alarm Output High (HDJ/Korea). . . . . . . . . E-47
DTC B1134 Starter Output High. . . . . . . . . . . . . . . . . . . 3-51
DTC B1134 Starter Output High (HDJ/Korea). . . . . . . . E-50
DTC B1135 Accelerometer Fault. . . . . . . . . . . . . . . . . . . 3-54
DTC B1135 Accelerometer Fault (HDJ/Korea). . . . . . . . E-53
DTC B1136 Accelerometer Tip-Over Self-Test Fault. . . . 3-54
DTC B1141 Ignition Switch Open/Low. . . . . . . . . . . . . . 3-54
DTC B1142 Internal Fault. . . . . . . . . . . . . . . . . . . . . . . . 3-54
DTC B1143 Security Antenna Short-to-Ground. . . . . . . 3-58
DTC B1144 Security Antenna Short-to-Battery. . . . . . . . 3-58
DTC B1145 Security Antenna Open. . . . . . . . . . . . . . . . 3-58
DTC B1154 Clutch Switch Short-to-Ground. . . . . . . . . . 3-61
DTC B1154 Clutch Switch Short-to-Ground (HDJ/Korea). E-54
DTC B1155 Neutral Switch Short-to-Ground. . . . . . . . . 3-61
DTC B1155 Neutral Switch Short-to-Ground
(HDJ/Korea). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-54
DTC P0107 MAP Sensor Open/Low. . . . . . . . . . . . . . . . 4-66
DTC P0112 IAT Sensor Voltage Low. . . . . . . . . . . . . . . . 4-66
DTC P0113 IAT Sensor Voltage Open/High. . . . . . . . . . 4-66
DTC P0117 ET Sensor Voltage Low. . . . . . . . . . . . . . . . 4-73
DTC P0118 ET Sensor Open/High. . . . . . . . . . . . . . . . . 4-73
DTC P0122 TP Sensor Open/Low. . . . . . . . . . . . . . . . . . 4-77
DTC P0123 TP Sensor High. . . . . . . . . . . . . . . . . . . . . . 4-77
DTC P0131 Front Oxygen Sensor Low or Engine Running
Lean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
DTC P0132 Engine Running Rich. . . . . . . . . . . . . . . . . . 4-82
DTC P0134 Front Oxygen Sensor Open/Not
Responding/High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
DTC P0151 Rear Oxygen Sensor Low or Engine Running
Lean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
DTC P0152 Engine Running Rich. . . . . . . . . . . . . . . . . . 4-82
DTC P0154 Rear Oxygen Sensor Open/Not
Responding/High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
DTC P0261 Front Injector Open/Low. . . . . . . . . . . . . . . 4-87
DTC P0262 Front Injector High. . . . . . . . . . . . . . . . . . . . 4-87
DTC P0263 Rear Injector Open/Low. . . . . . . . . . . . . . . . 4-87
DTC P0264 Rear Injector High. . . . . . . . . . . . . . . . . . . . 4-87
DTC P0373 CKP Sensor Intermittent. . . . . . . . . . . . . . . 4-93
DTC P0374 CKP Sensor Synch Error. . . . . . . . . . . . . . . 4-93
DTC P0501 VSS Sensor Low. . . . . . . . . . . . . . . . . . . . . 4-96
DTC P0502 VSS Sesnor High/Open. . . . . . . . . . . . . . . . 4-96
DTC P0505 Loss of Idle Speed Control. . . . . . . . . . . . . 4-55
DTC P0562 Battery Voltage Low. . . . . . . . . . . . . . . . . . 4-100
DTC P0563 Battery Voltage High. . . . . . . . . . . . . . . . . 4-100
DTC P0603 ECM EEPROM Error. . . . . . . . . . . . . . . . . 4-104
DTC P0605 ECM Flash Error. . . . . . . . . . . . . . . . . . . . 4-104
DTC P0661 Active Intake Solenoid Open/Low. . . . . . . 4-105
DTC P0662 Active Intake High/Shorted. . . . . . . . . . . . 4-105
DTC P1001 Ssytem Relay Coil Open/Low. . . . . . . . . . . 4-50
DTC P1002 System Relay Coil High/Shorted. . . . . . . . . 4-50
DTC P1003 System Relay Contacts Open. . . . . . . . . . . 4-50
DTC P1004 System Relay Contacts Closed. . . . . . . . . . 4-50
DTC P1009 Incorrect Password. . . . . . . . . . . . . . . . . . 4-109
DTC P1010 Missing Password. . . . . . . . . . . . . . . . . . . 4-109
DTC P1064 Loss of TSM/TSSM/HFSM Serial Data. . . 4-124

VII

INDEX

DTC P1097 Loss of All Speedometer Serial Data (State of
Health). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-129
DTC P1351 Front Ignition Coil Open/Low. . . . . . . . . . . 4-109
DTC P1352 Front Ignition Coil High/Shorted. . . . . . . . . 4-109
DTC P1354 Rear Ignition Coil Open/Low. . . . . . . . . . . 4-109
DTC P1355 Rear Ignition Coil High/Shorted. . . . . . . . . 4-109
DTC P1501 Jiffy Stand Sensor Low. . . . . . . . . . . . . . . 4-119
DTC P1502 Jiffy Stand Sensor High. . . . . . . . . . . . . . . 4-119
DTC P-1-8 MAP Sensor High. . . . . . . . . . . . . . . . . . . . . 4-66
DTC U1016 Loss of All ECM Serial Data. . . . . . . . . . . . 2-34
DTC U1016 Loss of All ECM Serial Data (State of
Health). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-58
DTC U1064 Loss of TSM/TSSM/HFSM Serial Data. . . . 2-39
DTC U1255 Missing Message at Speedometer. . . . . . 4-129
DTC U1255 Serial Data Error/Missing Message. . . . . . . 2-34
DTC U1255 Serial Data Error/Missing Message (ECM). 4-124
DTC U1255 Serial Data Error/Missing Message
(HDJ/Korea). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-58
DTC U1300 Serial Data Low. . . . . . . . . . . . . . . . . . . . . . 2-44
DTC U1300 Serial Data Low (ECM). . . . . . . . . . . . . . . . 4-36
DTC U1300 Serial Data Low (HDJ/Korea). . . . . . . . . . . E-63
DTC U1301 Serial Data Open/High. . . . . . . . . . . . . . . . 2-44
DTC U1301 Serial Data Open/High (ECM). . . . . . . . . . . 4-36
DTC U1301 Serial Data Open/High (HDJ/Korea). . . . . . E-63

Electronic Control Module (ECM). . . . . . . . . . . . . . . . . . . 4-3
Electronic Fuel Injection (EFI). . . . . . . . . . . . . . . . . . . . . . 4-3
ET Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Fluid Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Fuel Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Fuse Block Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17

Glossary

Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . D-1

Hands-Free Fob Battery. . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Hands-Free Security Module (HFSM). . . . . . . . . . . . . . . . 3-2

Idle Air Control Description. . . . . . . . . . . . . . . . . . . . . . . . 4-3
Idle Air Control Diagnostics. . . . . . . . . . . . . . . . . . . . . . . 4-55
Ignition Coil Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Ignition Coil Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 4-114
Indicator Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Intake Air Temperature (IAT)/Manifold Absolute Pressure
(TMAP) sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Jiffy Stand Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119

Key Fob Assignment:TSSM. . . . . . . . . . . . . . . . . . . . . . . E-4
Key Fob Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-65

Loctite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-II

Main Fuse Housing

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24

Metric System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Metri-Pack Terminals

Crimping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26

Molex Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28

Odometer Theory of Operation. . . . . . . . . . . . . . . . . . . . 2-15
Oxygen Sensor Description. . . . . . . . . . . . . . . . . . . . . . . . 4-3
Oxygen Sensor Diagnostics. . . . . . . . . . . . . . . . . . . . . . 4-82

Packard 100W Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30

Packard Micro-64 Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-32

Personal Identification Number. . . . . . . . . . . . . . . . . . . . . 3-6
PIN Entry:TSSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Reprogramming ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Sealed Splice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-35
Security Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Security Lamp (HDJ/Korea). . . . . . . . . . . . . . . . . . . . . . E-13
Security Lamp (Key Icon). . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Security Lamp Diagnostics. . . . . . . . . . . . . . . . . . . . . . . 3-13
Security Lamp Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Security System Functions (TSSM Only). . . . . . . . . . . . E-10
Service/Emergency Functions. . . . . . . . . . . . . . . . . . . . . 3-11
Service Bulletins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-I
Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-I
Sidecar Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Sidecar Configuration (HDJ/Korea). . . . . . . . . . . . . . . . . . E-4
Siren. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Siren Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Siren Battery (HDJ/Korea). . . . . . . . . . . . . . . . . . . . . . . E-65
Speedometer Functions. . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Speedometer Theory of Operation. . . . . . . . . . . . . . . . . 2-15
SPX Kent-Moore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-II
Starter

Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Starter Activation Circuits. . . . . . . . . . . . . . . . . . . . . . . . 1-12
Starter Current Draw Test. . . . . . . . . . . . . . . . . . . . . . . . 1-13
Starter Free Running Current Draw Test. . . . . . . . . . . . . 1-15
Starter Solenoid

Solenoid Hold-In Test. . . . . . . . . . . . . . . . . . . . . . . . 1-15
Solenoid Pull-In Test. . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Solenoid Return Test. . . . . . . . . . . . . . . . . . . . . . . . 1-16

Starter Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Starting System Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . 1-3
Start Relay Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
System Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Tachometer Theory of Operation. . . . . . . . . . . . . . . . . . . 2-15
Throttle Position (TP) Sensor Description. . . . . . . . . . . . . 4-3
Throttle Position (TP) Sensor Diagnostics. . . . . . . . . . . . 4-77

VIII INDEX

TMAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Torque Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Trademarks

Harley-Davidson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-II
Referenced Products. . . . . . . . . . . . . . . . . . . . . . . . . . I-II

Trip Odometer Reset Switch. . . . . . . . . . . . . . . . . . . . . . 2-15
TSM/HFSM: Password Learn. . . . . . . . . . . . . . . . . . . . . 3-71
TSM/TSSM: Password Learn. . . . . . . . . . . . . . . . . . . . . E-64
Turn Signal Errors: B1121, B1122, B1141. . . . . . . . . . . E-33
Turn Signal Functions

4-Way Flashing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Automatic Cancellation. . . . . . . . . . . . . . . . . . . . . . . E-8
Manual Cancellation. . . . . . . . . . . . . . . . . . . . . . . . . E-8

Turn Signal Module Function. . . . . . . . . . . . . . . . . . . . . . . 3-1

Vehicle Speed Sensor (VSS) Description. . . . . . . . . . . . . 4-3
Vehicle Speed Sensor (VSS) Diagnostics. . . . . . . . . . . . 4-96

Wiggle Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
WOW Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
WOW Test (HDJ/Korea). . . . . . . . . . . . . . . . . . . . . . . . . E-26

INDEX IX

NOTES

TORQUE VALUE

FASTENER

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

3.16 TOP END OVERHAUL:
ASSEMBLY, Assembling Motorcycle After Top End
Repair

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

3.25 OIL PUMP: XR MODELS, Assembly

9.0-12.4 Nm

80-110 in-lbs

Gearcase/oil pump housing cover
fastener

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Gears and Gearcase Cover: XR
Models

9.0-12.4 Nm

80-110 in-lbs

Gearcase and oil pump cover fastener

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Gears and Gearcase Cover: XR
Models

9.0-12.4 Nm

80-110 in-lbs

Gearcase cover fastener: XR models

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Gears and Gearcase Cover: XL
Models

9.0-12.4 Nm

80-110 in-lbs

Gearcase cover screw

3.25 OIL PUMP: XR MODELS, Assembly

12.2-17.6 Nm

108-156 in-lbs

Gearcase housing plug

3.24 OIL PUMP: XL MODELS, Installation

6.8-10.2 Nm

60-90 in-lbs

High pressure feed hose fitting (to
crankcase)

3.24 OIL PUMP: XL MODELS, Installation

9.6-11.8 Nm

85-105 in-lbs

High pressure feed hose fitting nut

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

4.0-5.1 Nm

34-45 in-lbs

Ignition switch mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

4.0-5.1 Nm

34-45 in-lbs

Ignition switch mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

27.1-32.5 Nm

20-24 ft-lbs

Induction module cover-to-cylinder head
fastener

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-induction
module fastener

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

9.5-12.2 Nm

84-108 in-lbs

Induction module cover-to-wire form
fastener

3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers

24.4-29.8 Nm

18-22 ft-lbs

Inner rocker cover bolt, large

3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers

15.3-17.5 Nm

135-155 in-lbs

Inner rocker cover bolt, small

3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers

15.3-17.5 Nm

135-155 in-lbs

Inner rocker cover screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

33.9-47.5 Nm

25-35 ft-lbs

Isolator mount screw, front

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

33.9-47.5 Nm

25-35 ft-lbs

Isolator mount screw, front

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

33.9-47.5 Nm

25-35 ft-lbs

Isolator mount screw, rear

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

33.9-47.5 Nm

25-35 ft-lbs

Isolator mount screw, rear

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

61.0-67.8 Nm

45-50 ft-lbs

Lower front retainer plate fastener

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

40.7-61.0 Nm

30-45 ft-lb

Lower shock absorber fastener

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models/Apply Loctite Threadlocker 243
(blue)

4.1-6.8 Nm

36-60 in-lbs

Oil cooler fastener

HOME

3-2 2009 Sportster Service: Engine

NOTES

TORQUE VALUE

FASTENER

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Oil Cooler/Apply Loctite Threadlocker
243 (blue)

4.1-6.8 Nm

36-60 in-lbs

Oil cooler fastener

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase

2.8-3.9 Nm

25-35 in-lbs

Oil deflector plate screw

3.26 OIL FILTER MOUNT, Assembly

10.9-16.3 Nm

96-144 in-lbs

Oil filter adapter

3.26 OIL FILTER MOUNT, Assembly

5.6-7.9 Nm

50-70 in-lbs

Oil pressure indicator switch

3.24 OIL PUMP: XL MODELS, Assembly

7.9-9.0 Nm

70-80 in-lbs

Oil pump cover screws

3.24 OIL PUMP: XL MODELS, Installation

6.2-7.4 Nm

55-65 in-lbs

Oil pump feed fitting

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Gears and Gearcase Cover: XR
Models

9.0-12.4 Nm

80-110 in-lbs

Oil pump rotor cover screw: XR models

3.25 OIL PUMP: XR MODELS, Assembly

9.0-12.4 Nm

80-110 in-lbs

Oil pump rotor cover screw: XR models

3.24 OIL PUMP: XL MODELS, Installation

14.1-16.9 Nm

125-150 in-lbs

Oil pump-to-crankcase screw

3.27 OIL TANK, Installation

4.1-6.8 Nm

36-60 in-lbs

Oil tank mounting screw

3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers

13.5-19.0 Nm

120-168 in-lbs

Outer rocker cover screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

61-68 Nm

45-50 ft-lbs

Passenger footrest support bracket
screw

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Gears and Gearcase Cover: XL
Models

26-29 Nm

19-21 ft-lbs

Pinion shaft locking nut

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Gears and Gearcase Cover: XR
Models

26-29 Nm

19-21 ft-lbs

Pinion shaft locking nut

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase

2.8-4.0 Nm

25-35 in-lbs

Piston oil jet screw

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

9.5-12.2 Nm

84-108 in-lbs

Precision cooling check valve housing
fastener

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Gears and Gearcase Cover: XR
Models

9.5-12.2 Nm

84-108 in-lbs

Precision cooling check valve housing
fastener

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

20.3-28.5 Nm

15-21 ft-lbs

Precision cooling check valve plug fitting

3.16 TOP END OVERHAUL: ASSEMBLY, Push
Rods, Covers, and Retainers

9.0-12.4 Nm

80-110 in-lbs

Push rod retainer screw

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Oil Pump Lines

12.2-17.6 Nm

108-156 in-lbs

Quick connect fitting

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Return Lines

12.2-17.6 Nm

108-156 in-lbs

Quick connect fitting, cylinder head
return oil

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

81.4-95.0 Nm

60-70 ft-lbs

Rear fork pivot/engine mount bolt

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

81.4-95.0 Nm

60-70 ft-lbs

Rear fork pivot/engine mount bolt

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Cylinder Head Oil Return Lines

9.5-12.2 Nm

84-108 in-lbs

Rear rigid oil line retainer screw

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Oil Pump Lines

9.5-12.2 Nm

84-108 in-lbs

Rear rigid oil line retainer screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

8.1-13.6 Nm

72-120 in-lbs

Rear stop light switch bracket screw

3.14 PRECISION COOLING SYSTEM: XR
MODELS, Return Oil Manifold

9.5-12.2 Nm

84-108 in-lbs

Return oil manifold screw

HOME

2009 Sportster Service: Engine 3-3

NOTES

TORQUE VALUE

FASTENER

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

13.6-20.3 Nm

10-15 ft-lbs

Shift linkage pivot bolt

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

23.0-29.8 Nm

17-22 ft-lbs

Siren/canister bracket; rear brake line
fastener

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

40.7-44.8 Nm

30-33 ft-lbs

Sprocket cover fastener, large: XR
models

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

9.0-13.6 Nm

80-120 in-lbs

Sprocket cover fastener, small: XR
models

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

9.0-13.6 Nm

80-120 in-lbs

Sprocket cover screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (lower front) frame bracket
mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (lower front) frame bracket
mounting screw

3.16 TOP END OVERHAUL:
ASSEMBLY, Assembling Motorcycle After Top End
Repair

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (lower front) frame bracket
mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (upper front) frame bracket
mounting screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (upper front) frame bracket
mounting screw

3.16 TOP END OVERHAUL:
ASSEMBLY, Assembling Motorcycle After Top End
Repair

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link (upper front) frame bracket
mounting screw

3.21 CYLINDER HEAD, Assembly

74.6-88.2 Nm

55-65 ft-lbs

Stabilizer link bracket to front head
screws and lock washers

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XL Models

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

3.13 INSTALLING ENGINE IN CHASSIS, Pro-
cedure: XR Models

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

HOME

3-4 2009 Sportster Service: Engine

3.2

SPECIFICATIONS

SPECIFICATIONS: 2009 SPORTSTER
MODELS

Service wear limits are given as a guideline for measuring
components that are not new. Replace components when their

measurements exceed values listed in the SERVICE WEAR
LIMITS columns.

Table 3-1. Engine: 2009 Sportster Models

XR 1200

MODEL

XL 1200

MODELS

XL 883

MODELS

ITEM

Number of cylinders

4-cycle, 45 degree, V-Type, air cooled

Type

10.0-1

9.7-1

8.9-1

Compression ratio

88.90 mm

3.500 in.

88.90 mm

3.500 in.

76.20 mm

3.000 in.

Bore

96.82 mm

3.812 in.

96.82 mm

3.812 in.

96.82 mm

3.812 in.

Stroke

1202.81 cu. cm

73.40 cu. in.

1202.81 cu. cm

73.40 cu. in.

883.10 cu. cm

53.89 cu. in.

Displacement

N/A

107.12 Nm

79.00 ft-lbs

74.58 Nm

55.00 ft-lbs

Torque (North
America)

@ 4000 RPM

@ 3500 RPM

99.80 Nm

73.60 ft-lbs

101.70 Nm

75.00 ft-lbs

71.87 Nm

53.00 ft-lbs

Torque (World)

@ 4000 RPM

@ 3500 RPM

@ 4500 RPM

92.34 Nm

68.10 ft-lbs

89.50 Nm

66.00 ft-lbs

65.09 Nm

48.00 ft-lbs

Torque (Japan)

@ 3500 RPM

Table 3-2. Cylinder Heads-883 cc/1200 cc

SERVICE WEAR LIMITS

NEW COMPONENTS

ITEM

0.084-0.051 mm

0.0033-0.0020 in.

Valve guide in head
(tight)

0.089-0.025 mm

0.0035-0.0010 in.

Valve seat in head

Replace if more than

0.152 mm

Replace if more than

0.006 in.

0.152 mm

0.006 in.

Head gasket surface
(flatness)

Table 3-3. Rocker Arms and Shafts-883 cc/1200 cc

SERVICE WEAR LIMITS

NEW COMPONENTS

ITEM

0.0889 mm

0.0035 in.

0.013-0.051 mm

0.0005-0.0020 in.

Shaft in bushing (loose)

0.635 mm

0.025 in.

0.08-0.33 mm

0.003-0.013 in.

End clearance

0.10-0.05 mm

0.004-0.002 in.

Bushing fit in rocker arm

0.0889 mm

0.0035 in.

0.018-0.056 mm

0.0007-0.0022 in.

Shaft fit in rocker cover

HOME

2009 Sportster Service: Engine 3-5

Table 3-4. Valves-883 cc/1200 cc

SERVICE WEAR LIMITS

NEW COMPONENTS

ITEM

0.0965 mm

0.0038 in.

0.0254-0.0762 mm

0.001-0.003 in.

Fit in guide
(intake/exhaust)

2.286 mm

0.090 in.

1.02-1.57 mm

0.040-0.062 in.

Seat width

52.883 mm

2.082 in.

51.511-52.426 mm

2.028-2.064 in.

Stem protrusion from
cylinder valve pocket

Table 3-5. Valve Springs (Intake/Exhaust)-883 cc/1200 cc

SERVICE WEAR LIMITS

NEW COMPONENTS

ITEM

61.2 kg @ 47.0 mm

135 lbs @ 1.850 in.

Closed

141.5 kg @ 33.0 mm

312 lbs @ 1.300 in.

Open

59.1 mm (min)

2.325 in. (min)

59.1 mm

2.325 in.

Free length

Table 3-6. Tappets-883 cc/1200 cc

SERVICE WEAR LIMITS

NEW COMPONENTS

ITEM

0.0762 mm

0.003 in.

0.020-0.058 mm

0.0008-0.0023 in.

Fit in guide

0.015-0.033 mm

0.0006-0.0013 in.

Roller fit

0.660 mm

0.026 in.

0.203-0.559 mm

0.008-0.022 in.

Roller end clearance

Table 3-7. Cylinder Bore-883 cc

SERVICE WEAR LIMITS

NEW COMPONENTS

BORE DIAMETER

76.289 mm

3.0035 in.

76.213 mm

3.0005 in.

Standard +/-0.0002 in.
(0.0051 mm)

76.398 mm

3.0078 in.

76.323 mm

3.0048 in.

0.005 in. O.S. (oversize)
+/-0.0002 in. (0.0051
mm)

76.525 mm

3.0128 in.

76.449 mm

3.0098 in.

0.010 in. O.S. +/-0.0002
in. (0.0051 mm)

76.779 mm

3.0228 in.

76.703 mm

3.0198 in.

0.020 in. O.S. +/-0.0002
in. (0.0051 mm)

0.0508 mm

0.002 in.

Taper

0.0762 mm

0.003 in.

Out of round

0.152 mm

0.006 in.

Top gasket surface
warpage

0.203 mm

0.008 in.

Base gasket surface
warpage

HOME

3-6 2009 Sportster Service: Engine

Table 3-8. Cylinder Bore-1200 cc

SERVICE WEAR LIMITS

NEW COMPONENTS

BORE DIAMETER

88.920 mm

3.5008 in.

88.844 mm

3.4978 in.

Standard +/-0.0002 in.
(0.0051 mm)

89.027 mm

3.505 in.

88.95 mm

3.502 in.

0.005 in. O.S. (oversize)
+/-0.0002 in. (0.0051
mm)

89.154 mm

3.510 in.

89.08 mm

3.507 in.

0.010 in. O.S. +/-0.0002
in. (0.0051 mm)

89.408 mm

3.520 in.

89.33 mm

3.517 in.

0.020 in. O.S. +/-0.0002
in. (0.0051 mm)

0.0508 mm

0.002 in.

Taper

0.0762 mm

0.003 in.

Out of round

0.152 mm

0.006 in.

Top gasket surface
warpage

0.203 mm

0.008 in.

Base gasket surface
warpage

XR Models: Oversized pistons are not available. Replace piston and/or cylinder as needed.

Table 3-9. Pistons-883 cc

SERVICE WEAR LIMITS

NEW COMPONENTS

ITEM

0.813 mm

0.032 in.

0.25-0.58 mm

0.010-0.023 in.

Compression ring gap
(top and 2nd)

1.651 mm

0.065 in.

0.25-1.35 mm

0.010-0.053 in.

Oil control ring rail gap

0.165 mm

0.0065 in.

0.051-0.114 mm

0.0020-0.0045 in.

Top compression ring
side clearance

0.165 mm

0.0065 in.

0.051-0.114 mm

0.0020-0.0045 in.

2nd compression ring
side clearance

0.239 mm

0.0094 in.

0.036-0.188 mm

0.0014-0.0074 in.

Oil control ring side
clearance

0.0013-0.0114 mm

0.00005-0.00045 in.

Piston pin fit (loose;
room temperature)

0.076 mm

0.0030 in.

0.038-0.066

0.0015-0.0026 in.

Piston fit in cylinder
(loose; room temper-
ature)

Table 3-10. Pistons-1200 cc

SERVICE WEAR LIMITS

NEW COMPONENTS

ITEM

0.813 mm

0.032 in.

0.18-0.51 mm

0.007-0.020 in.

Compression ring gap
(top and 2nd)

1.651 mm

0.065 in.

0.23-1.32 mm

0.009-0.052 in.

Oil control ring rail gap

0.165 mm

0.0065 in.

0.051-0.114 mm

0.0020-0.0045 in.

Top compression ring
side clearance

0.165 mm

0.0065 in.

0.041-0.104 mm

0.0016-0.0041 in.

2nd compression ring
side clearance

HOME

2009 Sportster Service: Engine 3-7

Content .. 54 55 56 57 ..