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
IX
T
ORQ
UE
V
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
. 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
for proper functionality.
Diagnostic Notes
Each reference number below correlates to a circled number
on the flowchart(s).
1.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B), brown pin probe and patch cord.
2.
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
2-26 2009 Sportster Diagnostics: Instruments
1
2
6
5
9
7
1
2
6
5
9
7
1
3
2
4
[91A]
12
10
10
7
1
6
2
12
7
1
6
2
3 2 1
3 2 1
4
1
3
2
4
1
3
2
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
GND 1
[GND1]
System
Relay
BN/GY
BN/GY
BN/GY
R/GY
Data Link
Connector
Fuel Pump And
Low Fuel Switch
Fuel Sender
Resistor
Assembly
2000
2000
[86]
BK
BK
BK
GY
GY
BK
BK
BK
BK
BK
Y/GN
Y/W
Y/W
Y/W
Y/W
Y/W
Y/R
Y/R
O
O
O
R
O
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
BN/GY
O/GY
O/GY
R/BK
R/BK
O/W
O/W
O/W
O/W
ECM
Ser
ial
Data
5
5
[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]
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
NO
Replace fuel level switch.
6035
Disconnect [200].
Is there continuity to
ground?
NO
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
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
NO
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
NO
Check continuity to ground on terminal
4 of connector [141A] (BK).
Is continuity present?
Locate and repair short
to voltage.
YES
NO
Replace fuel sender
resistor assembly.
Locate and repair open on
(BK) wire (ground circuit).
1
1
2
1
6083
6069
6069
6069
Clear DTCs using odometer self-diagnostics. See 2.3
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.
fc01818_en
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
2-30 2009 Sportster Diagnostics: Instruments
DTCs B1006 and B1007
Has battery charger been
recently connected?
YES
NO
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
NO
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
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).
1.
Disconnect speedometer connector [39] on XL, or tacho-
meter connector [108] on XR (at the back of the speedo-
meter). See
.
2.
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.
8
11
8
11
Trip SW
Trip SW
Reset
Switch
BK
BK
BK
BK
[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]
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
NO
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?
1
YES
NO
Replace speedometer on
XL, or tachometer on XR.
Replace trip odometer
reset switch.
Replace boot.
fc01820_en
2
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).
1.
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.
Use ECM BREAKOUT BOX (Part No. HD-48637).
2-34 2009 Sportster Diagnostics: Instruments
BK
BK
BK
GY
GY
GY
O/W
O/W
O/W
O/W
O
O
O
R
BN/GY
BN/GY
BN/GY
BN/GY
BN/GY
LGN/V
BK
BK
BK
O/W
O
O
BN/GY
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
R/BK
R/BK
R/GY
1 2
3
12
1 2
3
12
1 2
5
7
6
1 2
5
7
6
1 2
5 6 7
1 2
5 6 7
Ignition
Ser
ial
data
Batter
y
Accessor
y
Ground
Ignition
Ser
ial
Data
Batter
y
Batter
y
Ignition
Ser
ial
Data
Ground
Accessor
y
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
3
1
2
4
Data Link
Connector
2
1
6
7
12
2
1
6
7
12
ECM
Ser
ial
Data
5
5
GND1
GND1
GND1
[78B]
[78A]
[30A]
[30B]
[20A]
[20B]
[108A]
[108B]
[39A]
[39B]
[91A]
Ground
Serial Data
Power
em01120
Figure 2-20. Serial Data Circuit (XL)
2009 Sportster Diagnostics: Instruments 2-35
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