Content .. 73 74 75 76 ..

Harley Davidson Sportster Models 2009. Service Repair Manual - page 75

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

4.4 AIR CLEANER: XL MODELS, Installation

13.6-16.3 Nm

120-144 in-lbs

Air cleaner breather screw

1.4 MAINTENANCE SCHEDULE, General

4.1-6.8 Nm

36-60 in-lbs

Air cleaner cover screw

1.24 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

4.1-6.8 Nm

36-60 in-lbs

Air cleaner cover screw

1.4 MAINTENANCE SCHEDULE, General

4.5-6.8 Nm

40-60 in-lbs

Air filter element screw

1.24 AIR CLEANER: XL MODELS, Installation

4.5-6.8 Nm

40-60 in-lbs

Air filter element screw

4.4 AIR CLEANER: XL MODELS, Installation

4.5-6.8 Nm

40-60 in-lbs

Air filter screw

6.29 ALTERNATOR, Assembly and Installation

13.6-15.8 Nm

120-140 in-lbs

Alternator rotor-to-sprocket screw

6.29 ALTERNATOR, Assembly and Installation

3.4-4.5 Nm

30-40 in-lbs

Alternator stator mounting screw

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Tappets

9.0-12.4 Nm

80-110 in-lbs

Anti-rotation device mounting screw

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installation

28.5-36.6 Nm

21-27 ft-lbs

Axle (front) pinch screw

2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation

55.6-65.1 Nm

41-48 in-lbs

Axle (front) pinch screw

2.4 WHEELS, Front Wheel

28.5-36.6 Nm

21-27 ft-lbs

Axle (front) pinch screw: XL Models

2.4 WHEELS, Front Wheel

55.6-65.1 Nm

41-48 ft-lbs

Axle (front) pinch screw: XR Models

2.4 WHEELS, General

81-88 Nm

60-65 ft-lbs

Axle nut, front

2.4 WHEELS, Front Wheel

81-88 Nm

60-65 ft-lbs

Axle nut, front

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installation

81-88 Nm

60-65 ft-lbs

Axle nut, front

2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation

81-88 Nm

60-65 ft-lbs

Axle nut, front

1.16 REAR BELT DEFLECTION, Belt Deflection
Adjustment

129-142 Nm

95-105 ft-lbs

Axle nut, rear

1.16 REAR BELT DEFLECTION, Wheel Alignment

129-142 Nm

95-105 ft-lbs

Axle nut, rear

2.4 WHEELS, General

129-142 Nm

95-105 ft-lbs

Axle nut, rear

2.4 WHEELS, Rear Wheel

129-142 Nm

95-105 ft-lbs

Axle nut, rear

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

129-142 Nm

95-105 ft-lbs

Axle nut, rear

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

129-142 Nm

95-105 ft-lbs

Axle nut, rear

5.7 DRIVE BELT, Installation

129-142 Nm

95-105 ft-lbs

Axle nut, rear

5.7 DRIVE BELT, Installation

129-142 Nm

95-105 ft-lbs

Axle nut, rear

6.24 TURN SIGNALS, Front Housing Replacement

10.8-17.6 Nm

96-156 in-lbs

Ball head studs (front turn signals)

1.17 BATTERY MAINTENANCE, Battery Installa-
tion and Connection

6.2-8.5 Nm

55-75 in-lbs

Battery cable connector nut

6.11 BATTERY CABLES, Installation

6.2-8.5 Nm

55-75 in-lbs

Battery negative cable-to-crankcase nut

1.4 MAINTENANCE SCHEDULE, General

6.8-7.9 Nm

60-70 in-lbs

Battery negative terminal screw

1.17 BATTERY MAINTENANCE, Battery Installa-
tion and Connection

6.8-7.9 Nm

60-70 in-lbs

Battery negative terminal screw

6.11 BATTERY CABLES, Installation

6.8-7.9 Nm

60-70 in-lbs

Battery negative terminal screw

1.17 BATTERY MAINTENANCE, Battery Installa-
tion and Connection

6.8-7.9 Nm

60-70 in-lbs

Battery positive terminal screw

6.11 BATTERY CABLES, Installation

6.8-7.9 Nm

60-70 in-lbs

Battery positive terminal screw

1.17 BATTERY MAINTENANCE, Battery Installa-
tion and Connection

4.1-6.8 Nm

36-60 in-lbs

Battery strap screw

6.11 BATTERY CABLES, Installation

4.1-6.8 Nm

36-60 in-lbs

Battery strap screw

2.22 FRONT FORK: XR MODELS, Installation

6.8-7.9 Nm

60-70 in-lbs

Battery terminal bolts

ORQ

ALUES

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

6.12 BATTERY TRAY, Installation

10.9-17.6 Nm

96-156 in-lbs

Battery tray mounting screw

5.7 DRIVE BELT, Installation

13.6-20.3 Nm

120-180 in-lbs

Belt guard screw, front

2.24 BELT GUARD AND DEBRIS
DEFLECTOR, Belt Guard: XL Models

13.6-20.4 Nm

120-180 in-lbs

Belt guard screw, front (XL)

2.24 BELT GUARD AND DEBRIS
DEFLECTOR, Belt Guard: XR Models

8.1-10.8 Nm

72-96 in-lbs

Belt guard screw (XR), front

1.8 BLEEDING HYDRAULIC BRAKE
SYSTEM, Bleeding Front Brake: All Models

4.0-6.9 Nm

35-61 in-lbs

Bleeder valve

1.8 BLEEDING HYDRAULIC BRAKE
SYSTEM, Bleeding Rear Brake: All Models

4.0-6.9 Nm

35-61 in-lbs

Bleeder valve

2.4 WHEELS, Rear Wheel

40.7-61.1 Nm

30-45 ft-lbs

Brake (rear) disc screw

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

3.4-4.5 Nm

30-40 in-lbs

Brake (rear) hose clamp-to-frame screw

6.12 BATTERY TRAY, Installation

8.1-13.6 Nm

72-120 in-lbs

Brake (rear) lamp switch screw

2.18 BRAKE LINES, Rear Brake Line: XL Models

8.14-13.6 Nm

72-120 in-lbs

Brake (rear) line/switch tee bracket
screw

2.18 BRAKE LINES, Rear Brake Line: XR Models

1.9-2.5 Nm

17-22 in-lbs

Brake (rear) line/switch tee bracket
screw

2.12 FRONT BRAKE CALIPER: XR
MODELS, Assembly

16.9-24.5 Nm

12-18 ft-lbs

Brake bridge bolt, front caliper

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.11 FRONT BRAKE CALIPER: XL
MODELS, Assembly

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.12 FRONT BRAKE CALIPER: XR
MODELS, Assembly

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.18 BRAKE LINES, Front Brake Line: All Models

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.18 BRAKE LINES, Rear Brake Line: XL Models

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.18 BRAKE LINES, Rear Brake Line: XR Models

4.0-6.9 Nm

35-61 in-lbs

Brake caliper bleeder valve

2.4 WHEELS, Front Wheel/Cast front wheel

21.7-32.6 Nm

16-24 ft-lbs

Brake disc mounting screw

2.4 WHEELS, Front Wheel/Cast front wheel

21.7-32.6 Nm

16-24 ft-lbs

Brake disc mounting screw

2.4 WHEELS, Front Wheel/Laced front wheel

21.7-32.6 Nm

16-24 ft-lbs

Brake disc mounting screw

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installation

38.0-51.6 Nm

28-38 ft-lbs

Brake front caliper mounting bolt

2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation

38.0-51.6 Nm

28-38 ft-lbs

Brake front caliper mounting bolt

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

1.0-2.0 Nm

9-17 in-lbs

Brake front cover master cylinder reser-
voir cover screw

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

12.2-14.9 Nm

108-132 in-lbs

Brake front master cylinder clamp screw

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installation

1.0-2.0 Nm

9-17 in-lbs

Brake front master cylinder reservoir
cover screw

2.18 BRAKE LINES, Rear Brake Line: XL Models

3.4-4.5 Nm

30-40 in-lbs

Brake hose clamp-to-battery tray screw

6.12 BATTERY TRAY, Installation

3.4-4.5 Nm

30-40 in-lbs

Brake hose clamp-to-battery tray screw

1.16 REAR BELT DEFLECTION, Belt Deflection
Adjustment

3.4-4.5 Nm

30-40 in-lbs

Brake hose clamp-to-rear fork screw

2.18 BRAKE LINES, Rear Brake Line: XL Models

3.4-4.5 Nm

30-40 in-lbs

Brake hose clamp-to-rear fork screw

X TORQUE VALUES

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

2.18 BRAKE LINES, Rear Brake Line: XL Models

9.0-13.9 Nm

80-123 in-lbs

Brake lamp switch, rear

2.18 BRAKE LINES, Rear Brake Line: XR Models

9.0-13.9 Nm

80-123 in-lbs

Brake lamp switch, rear

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.12 FRONT BRAKE CALIPER: XR
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.16 REAR BRAKE CALIPER: XL
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.17 REAR BRAKE CALIPER: XR
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.18 BRAKE LINES, Front Brake Line: All Models

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.18 BRAKE LINES, Front Brake Line: All Models

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.18 BRAKE LINES, Rear Brake Line: XL Models

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.18 BRAKE LINES, Rear Brake Line: XR Models

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

2.18 BRAKE LINES, Front Brake Line: All Models

5.1-7.4 Nm

45-65 in-lbs

Brake line-to-front fork bracket clamp
screw

2.18 BRAKE LINES, Front Brake Line: All Models

13.6-19.0 Nm

120-168 in-lbs

Brake line-to-front fork lower bracket
clamp screw

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

14.8-19.6 Nm

131-173 in-lbs

Brake pad pin

1.10 BRAKE PADS AND DISCS: XR
MODELS, Brake Pad Replacement: Rear

14.8-19.6 Nm

131-173 in-lbs

Brake pad pin

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installing Brake Pads in Caliper

14.8-19.6 Nm

131-173 in-lbs

Brake pad pin

2.16 REAR BRAKE CALIPER: XL
MODELS, Installation

14.8-19.6 Nm

131-173 in-lbs

Brake pad pin

2.12 FRONT BRAKE CALIPER: XR
MODELS, Assembly

14.7-19.6 Nm

11-14 ft-lbs

Brake pad pin, front caliper

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

2.0-2.9 Nm

18-25 in-lbs

Brake pad pin plug

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

2.0-2.9 Nm

18-25 in-lbs

Brake pad pin plug

1.10 BRAKE PADS AND DISCS: XR
MODELS, Brake Pad Replacement: Rear

2.0-2.9 Nm

18-25 in-lbs

Brake pad pin plug

2.11 FRONT BRAKE CALIPER: XL
MODELS, Installing Brake Pads in Caliper

2.0-2.9 Nm

18-25 in-lbs

Brake pad pin plug

2.16 REAR BRAKE CALIPER: XL
MODELS, Installation

2.0-2.9 Nm

18-25 in-lbs

Brake pad pin plug

1.10 BRAKE PADS AND DISCS: XR
MODELS, Brake Pad Replacement: Front

14.8-19.6 Nm

131-173 in-lbs

Brake pad pins, front caliper

2.40 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS, Right
Footrest and Rear Brake Pedal Assembly

10.9-17.6 Nm

96-156 in-lbs

Brake pedal clevis screw

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS, Right
Footrest and Rear Brake Pedal Assembly

10.9-17.6 Nm

96-156 in-lbs

Brake pedal clevis screw

TORQUE VALUES XI

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake rear master cylinder banjo bolt;
XL models

2.14 REAR BRAKE MASTER CYLINDER: XR
MODELS, Installation

27.1-33.9 Nm

20-25 ft-lbs

Brake rear master cylinder banjo bolt;
XR models

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS, Installation

23.1-29.9 Nm

17-22 ft-lbs

Brake rear master cylinder mounting
bracket screw; XL models

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS, Installation

23.1-29.9 Nm

17-22 ft-lbs

Brake rear master cylinder mounting
bracket screw; XL models

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS, Installation

23.1-29.9 Nm

17-22 ft-lbs

Brake rear master cylinder mounting
screw; XL models

2.14 REAR BRAKE MASTER CYLINDER: XR
MODELS, Installation

8.1-10.9 Nm

72-96 in-lbs

Brake rear master cylinder mounting
screw; XR models

2.14 REAR BRAKE MASTER CYLINDER: XR
MODELS, Assembly

14.7-19.6 Nm

130-173 in-lbs

Brake rear master cylinder pushrod nut;
XR models

2.13 REAR BRAKE MASTER CYLINDER: XL
MODELS, Assembly

14.7-19.6 Nm

130-173 in-lbs

Brake rear master cylinder pushrod
shoulder nut

2.15 REAR BRAKE MASTER CYLINDER
RESERVOIR, Installation: XL Models

2.3-2.8 Nm

20-25 in-lbs

Brake rear master cylinder reservoir
mounting screw

2.25 REAR FORK, Installation

2.3-2.8 Nm

20-25 in-lbs

Brake rear master cylinder reservoir
mounting screw

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

2.3-2.8 Nm

20-25 in-lbs

Brake rear master cylinder reservoir
mounting screw

6.12 BATTERY TRAY, Installation

2.3-2.8 Nm

20-25 in-lbs

Brake rear master cylinder reservoir
mounting screw

6.27 REAR STOP LAMP SWITCH, Replacement

2.3-2.8 Nm

20-25 in-lbs

Brake rear master cylinder reservoir
mounting screw

2.15 REAR BRAKE MASTER CYLINDER
RESERVOIR, Installation: XR Models

4.1-6.8 Nm

36-60 in-lbs

Brake rear master cylinder reservoir
mounting screw; XR models

2.40 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS, Right
Footrest and Rear Brake Pedal Assembly

13.6-20.4 Nm

120-180 in-lbs

Brake rod-to-bell crank screw

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS, Right
Footrest and Rear Brake Pedal Assembly

13.6-20.4 Nm

120-180 in-lbs

Brake rod-to-bell crank screw

4.15 EXHAUST SYSTEM: XL MODELS, Installation

13.6-20.4 Nm

120-180 in-lbs

Brake rod-to-bell crank screw

2.40 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH MID-MOUNT CONTROLS, Right
Footrest and Rear Brake Pedal Assembly

13.6-20.4 Nm

120-180 in-lbs

Brake rod-to-brake pedal screw

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS, Right
Footrest and Rear Brake Pedal Assembly

13.6-20.4 Nm

120-180 in-lbs

Brake rod-to-brake pedal screw

3.16 TOP END OVERHAUL: ASSEMBLY, Rocker
Covers

4.0-6.2 Nm

35-55 in-lbs

Breather screw

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

14.8-19.6 Nm

131-173 in-lbs

Caliper pad pin

1.8 BLEEDING HYDRAULIC BRAKE
SYSTEM, Bleeding Front Brake: All Models

1.0-2.0 Nm

9-17 in-lbs

Captive screw

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

1.0-2.0 Nm

9-17 in-lbs

Captive screw

XII TORQUE VALUES

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

1.4 MAINTENANCE SCHEDULE, General

27.1-33.9 Nm

20-25 ft-lbs

Chain tensioner nut

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

4.1-12.2 Nm

36-108 in-lbs

Clutch cable end fitting

5.3 PRIMARY CHAIN ADJUSTER, Installation

4.1-6.8 Nm

36-60 in-lbs

Clutch cable end fitting

1.4 MAINTENANCE SCHEDULE, General

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

1.13 CLUTCH, Adjustment

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

1.14 TRANSMISSION LUBRICANT, Transmission
Lubrication: Sportster Models

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

5.3 PRIMARY CHAIN ADJUSTER, Installation

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

5.4 CLUTCH RELEASE MECHANISM, Assembly
and Installation

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

0.9-1.5 Nm

8-13 in-lbs

Clutch lever anti-rattle spring screw

2.31 CLUTCH CONTROL, Assembly and Installa-
tion

12.2-14.9 Nm

108-132 in-lbs

Clutch lever handlebar clamp screw

2.32 HANDLEBARS, Installation

12.2-14.9 Nm

108-132 in-lbs

Clutch lever handlebar clamp screw

6.19 IGNITION COIL, Installation

4.0-5.1 Nm

35-45 in-lbs

Coil mounting bracket screw

6.19 IGNITION COIL, Installation

2.7-8.1 Nm

24-72 in-lbs

Coil mounting screw

6.19 IGNITION COIL, Installation

2.7-8.1 Nm

24-72 in-lbs

Coil mounting screw

5.15 TRANSMISSION INSTALLATION, Shifter
Shaft Installation

44.8-50.2 Nm

33-37 ft-lbs

Countershaft retaining screw

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase

20.3-25.8 Nm

15-19 ft-lbs

Crankcase fastener

5.15 TRANSMISSION INSTALLATION, Assembling
Crankcases

20.3-25.8 Nm

15-19 ft-lbs

Crankcase fastener

6.28 CRANK POSITION SENSOR (CKP), Installa-
tion

9.0-11.3 Nm

80-100 in-lbs

Crank position sensor (CKP) screw

3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure

11-14 Nm

96-120 in-lbs

Cylinder head bolts

3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure

18-20 Nm

13-15 ft-lbs

Cylinder head bolts

3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure

11-14 Nm

96-120 in-lbs

Cylinder head bolts

3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See procedure

18-20 Nm

13-15 ft-lbs

Cylinder head bolts

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

23.1-32.6 Nm

17-24 ft-lbs

Cylinder head bracket screw

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

23.1-32.6 Nm

17-24 ft-lbs

Cylinder head bracket screw

4.17 FUEL INJECTORS, Installation

23.1-32.6 Nm

17-24 ft-lbs

Cylinder head bracket screw

2.10 FRONT BRAKE MASTER CYLINDER, Install-
ation

10.9-13.6 Nm

96-120 in-lbs

Cylinder head exhaust port nut

4.15 EXHAUST SYSTEM: XL MODELS, Installation

10.9-13.6 Nm

96-120 in-lbs

Cylinder head exhaust port nut

TORQUE VALUES XIII

2009 Sportster Models Service Manual

NOTES

TORQUE VALUE

FASTENER

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

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

29.8-35.3 Nm

22-26 ft-lbs

Cylinder head oil feed flare fitting, Preci-
sion Cooling

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

17.6-23.0 Nm

13-17 ft-lbs

Cylinder head oil feed line flare nut,
Precision 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

3.18 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase

13.6-27.1 Nm

120-240 in-lbs

Cylinder stud

2.24 BELT GUARD AND DEBRIS
DEFLECTOR, Debris Deflector: XL Models

4.1-6.8 Nm

36-60 in-lbs

Debris deflector screw (XL)

2.24 BELT GUARD AND DEBRIS
DEFLECTOR, Debris Deflector: XR Models

8.1-10.8 Nm

72-96 in-lbs

Debris deflector screw (XR)

6.17 ELECTRONIC CONTROL MODULE
(ECM), Installation

2.0-2.5 Nm

18-22 in-lbs

ECM fasteners: XR models

2.28 FRONT ENGINE MOUNT/ISOLATOR, Install-
ation

81.4-95.0 Nm

60-70 ft-lbs

Engine mount (front) bolt

5.6 PRIMARY DRIVE AND CLUTCH: XR
MODELS, Installation

210.0-224.0 Nm

155-165 ft-lbs

Engine sprocket bolt: XR Models

5.5 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Installation

326-353 Nm

240-260 ft-lbs

Engine sprocket nut

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

5.7 DRIVE BELT, Installation

9.0-13.6 Nm

80-120 in-lbs

Exhaust pipe clamp bracket final screws

5.7 DRIVE BELT, Installation

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket initial screw

2.29 REAR ENGINE MOUNT/ISOLATOR, Installa-
tion

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket screw

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

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket screw

4.15 EXHAUST SYSTEM: XL MODELS, Installation

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket screw

5.16 TRANSMISSION SPROCKET, Installation

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket screw

2.21 FRONT FORK: XL MODELS, Installation

10.9-17.6 Nm

96-156 in-lbs

Fender (front) mounting screw

2.34 REAR FENDER: ALL XL MODELS EXCEPT
XL 1200N, Installation

14.9-24.4 Nm

132-216 in-lbs

Fender (rear) mounting screw

6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)

14.9-24.4 Nm

132-216 in-lbs

Fender support screw with washer

XIV TORQUE VALUES

2.7

DTC B1004, B1005

GENERAL

See

Figure 2-16

. The fuel level is monitored by the speedo-

meter terminal "9" of connector [39] (Y/W) XL or Tachometer
connector [108] XR.

•

If the voltage on terminal "9" of connector [39] XL and
connector [108] XR exceeds the lower limit for greater
than or equal to 15 seconds, DTC B1004 will set.

•

If the voltage on terminal "9" of connector [39] XL and
connector [108] XR exceeds the upper limit (or is open)
for greater than or equal to 15 seconds, DTC B1005 will
set.

Table 2-7. Code Description

DESCRIPTION

DTC

Fuel level sending unit low

B1004

Fuel level sending unit high/open

B1005

ed02819

Figure 2-16. Speedometer Connector [39] on XL or

Tachometer [108] on XR (Typical)

DIAGNOSTICS

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-B

BREAKOUT BOX

HD-42682

INSTRUMENT HARNESS ADAPTERS

HD-46601

Diagnostic Tips

If fuel gauge is performing erratically (possible false DTCs),
review

Table 2-8

for proper functionality.

Diagnostic Notes

Each reference number below correlates to a circled number
on the flowchart(s).

Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B), brown pin probe and patch cord.

Connect BREAKOUT BOX (Part No. HD-42682) and
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601) between wire harness and speedometer XL or
tachometer XR.

Table 2-8. Testing Fuel Sender Resistor Assembly

[39B] PIN 2 RESISTANCE TO GROUND

FUEL LEVEL

2000 ohms ±200

Low

10000 ohms ±200

High

HOME

2-26 2009 Sportster Diagnostics: Instruments

1
2

[91A]

3 2 1

Ignition

Serial Data

Battery

Accessory

Ground

Fuel Level

12V

(Switched)

Accessory

Fuse

Battery

Fuse

Instrument

Fuse

12V

(Switched)

12V

(Switched)

12V

(BATT)

Ignition

Fuse

Fuel Pump

Fuse

GND 1

[GND1]

System

Relay

BN/GY

R/GY

Data Link
Connector

Fuel Pump And
Low Fuel Switch

Fuel Sender

Resistor

Assembly

2000

[86]

Y/GN

Y/W

Y/R

LGN/V

BN/GY

O/GY

R/BK

O/W

ECM

Ser

ial

Data

[78B]

[78A]

[141B]

[141A]

[20A]

[20B]

[200A]

[200B]

[39B]-XL

Speedometer-XL

[39A]

[108B]-XR

Tachometer-XR

[108A]

em01309

Figure 2-17. Fuel Sender Circuitry

Table 2-9. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under fuel tank

12-place Molex

Instruments

[20]

Back of speedometer

12-place Packard

Speedometer (XL)

[39]

Under seat

36-place Packard

ECM

[78]

On battery strap, behind left side cover

4-place Deutsch

Data link connector

[91A]

Back of tachometer

12-place Packard

Tachometer (XR)

[108]

Forward of relay/fuse blocks

4-place Molex

Fuel pump and low fuel switch

[141]

Under seat

3-place Molex

Fuel sender resistor assembly

[200]

HOME

2009 Sportster Diagnostics: Instruments 2-27

DTC B1004

Disconnect speedometer

connector [39] on XL, or

tachometer connector [108] on

XR.

Disconnect and measure

resistance between terminal 2

and terminal 4 of connector

[141A].

Is resistance between 1800

and 10200 ohms?

YES

Replace fuel level switch.

6035

Disconnect [200].

Is there continuity to

ground?

YES

Replace fuel sender

resistor assembly.

Locate and repair short to

ground in harness.

6083

7182

Clear DTCs using odometer self-diagnostics. See 2.3
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.

fc01949_en

HOME

2-28 2009 Sportster Diagnostics: Instruments

DTC B1005

Disconnect speedometer

connector [39] on XL, or

tachometer connector
[108] on XR. Measure

voltage on terminal 2 of

connector [141A] (Y/W).

Should be 0 volts.

Is it?

YES

Check continuity between terminal

2 of connector [141A] (Y/W) and

Breakout Box terminal 11 (BK).

Is continuity present?

Locate and repair short

to voltage.

YES

Check continuity to ground on terminal

4 of connector [141A] (BK).

Is continuity present?

Locate and repair short

to voltage.

YES

Replace fuel sender

resistor assembly.

Locate and repair open on

(BK) wire (ground circuit).

6083

6069

Clear DTCs using odometer self-diagnostics. See 2.3
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.

fc01818_en

HOME

2009 Sportster Diagnostics: Instruments 2-29

2.8

DTC B1006, B1007

GENERAL

Accessory or Ignition Line Overvoltage

Ignition and accessory voltage is constantly monitored by the
speedometer (terminal 1 ignition and terminal 6 accessory). If
the battery voltage fails to meet normal operating parameters,
a DTC is set.

•

DTC B1006 is displayed when accessory line voltage is
greater than 16.0 volts for longer than 5 seconds.

•

DTC B1007 is displayed when ignition line voltage is
greater than 16.0 volts for longer than 5 seconds.

NOTE

ECM or TSM/TSSM/HFSM may also set a battery voltage DTC.

Table 2-10. Code Description

DESCRIPTION

DTC

Accessory line overvoltage

B1006

Ignition line overvoltage

B1007

HOME

2-30 2009 Sportster Diagnostics: Instruments

DTCs B1006 and B1007

Has battery charger been

recently connected?

YES

Diagnose charging system.

See 1.7 CHARGING SYSTEM.

NOTE

Sometimes battery charger may

cause over voltage condition which

will set codes.

Clear codes.

Start vehicle. Run at 3000

RPM for 5 seconds.

Does code reset?

YES

Diagnose charging

system.

See 1.7 CHARGING

SYSTEM.

System normal.

Clear DTCs using odometer self-diagnostics. See 2.3
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.

fc01819_en

HOME

2009 Sportster Diagnostics: Instruments 2-31

2.9

DTC B1008

GENERAL

Trip Odometer Reset Switch Closed

Diagnostic Trouble Code (DTC) B1008 will be set if trip odo-
meter reset switch terminals are in a constant shorted state.

ed02816

Figure 2-18. Trip Odometer Reset Switch (Typical)

Table 2-11. Code Description

DESCRIPTION

DTC

Trip odometer reset switch closed

B1008

DIAGNOSTICS

TOOL NAME

PART NUMBER

BREAKOUT BOX

HD-42682

INSTRUMENT HARNESS ADAPTERS

HD-46601

Diagnostic Notes

Each reference number below correlates to a circled number
on the flowchart(s).

Disconnect speedometer connector [39] on XL, or tacho-
meter connector [108] on XR (at the back of the speedo-
meter). See

2.5 BREAKOUT BOX: SPEEDO-

METER/TACHOMETER

Connect BREAKOUT BOX (Part No. HD-42682) (black)
to wire harness connector [39B] on XL, wire harness
connector [108B] on XR using INSTRUMENT HARNESS
ADAPTERS (Part No. HD-46601), leaving speedometer
XL, or tachometer XR disconnected.

Trip SW

Reset
Switch

[39B]-XL

Speedometer-XL

[39A]

[108B]-XR

Tachometer-XR

[108A]

em01310

Figure 2-19. Trip Odometer Reset Switch Circuit

Table 2-12. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Back of speedometer

12-place Packard

Speedometer (XL)

[39]

Back of tachometer

12-place Packard

Tachometer (XR)

[108]

HOME

2-32 2009 Sportster Diagnostics: Instruments

DTC B1008

Remove trip odometer reset switch rubber

boot.

Clear codes. See 2.3 ODOMETER SELF-

DIAGNOSTICS.

Are codes still present?

Clear DTCs using odometer self-diagnostics. See 2.3
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.

YES

With speedometer connector [39]

on XL, or tachometer connector

[108] on XR disconnected,

measure resistance between

Breakout Box terminal 8 and 11

(black). Resistance should be less

than 1 ohm with switch depressed

and infinity ohms when released.

Is it?

YES

Replace speedometer on

XL, or tachometer on XR.

Replace trip odometer

reset switch.

Replace boot.

fc01820_en

HOME

2009 Sportster Diagnostics: Instruments 2-33

2.10

DTC U1016, U1255

GENERAL

Loss of ECM Serial Data

The serial data line provides a means for the ECM,
TSM/TSSM/HFSM, speedometer on XL and tachometer on
XR to communicate their current status. When all operating
parameters on the serial data line are within specifications, a
state of health message is sent between the components.

•

DTC U1016 indicates that the ECM is not capable of
sending this state of health message.

•

DTC U1255 indicates that no messages were present
during power up of the current key cycle.

•

DTC U1016 indicates that there was communication on
the data bus since power up, but communication was lost
or interrupted during that key cycle.

Table 2-13. Code Description

DESCRIPTION

DTC

Loss of all ECM serial data (state of health)

U1016

Serial data error/missing message

U1255

DIAGNOSTICS

TOOL NAME

PART NUMBER

BREAKOUT BOX

HD-42682

INSTRUMENT HARNESS ADAPTERS

HD-46601

ECM BREAKOUT BOX

HD-48637

Diagnostic Notes

Each reference number below correlates to a circled number
on the flowchart(s).

Connect BREAKOUT BOX (Part No. HD-42682) (black)
between speedometer connector [39A] on XL, or tacho-
meter connector [108A] on XR and wire harness connector
[39B] on XL, or wire harness connector [108B] on XR using
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601). See

2.5 BREAKOUT BOX: SPEEDO-

METER/TACHOMETER

Use ECM BREAKOUT BOX (Part No. HD-48637).

HOME

2-34 2009 Sportster Diagnostics: Instruments

O/W

BN/GY

LGN/V

O/W

BN/GY

LGN/V

R/BK

R/GY

1 2

5 6 7

1 2

5 6 7

Ignition

Ser

ial

data

Batter

Accessor

Ground

Ignition

Ser

ial

Data

Batter

Ignition

Ser

ial

Data

Ground

Accessor

Ground

Speedometer

TSM/TSSM/HFSM

Tachometer (Optional)

To ACCY Fuse

To BATT Fuse

To INSTR Fuse

To IGN Fuse

12V ACCY

Fuse

12V BATT

Fuse

12V INSTR

Fuse

12V IGN

Fuse

Data Link
Connector

ECM

Ser

ial

Data

GND1

[78B]

[78A]

[30A]

[30B]

[20A]

[20B]

[108A]

[108B]

[39A]

[39B]

[91A]

Ground

Serial Data

Power

em01120

Figure 2-20. Serial Data Circuit (XL)

HOME

2009 Sportster Diagnostics: Instruments 2-35

Content .. 73 74 75 76 ..