Harley Davidson Sportster Models 2009. Service Repair Manual — page 33
15
11
14
13
12
10
9
8
6
5
4
7
3
16
2
1
sm05421
1.
TP sensor
2.
O-ring
3.
IAC
4.
Fuel hose
5.
Nylon washer (included with hose (4))
6.
O-ring (included with hose (4))
7.
Retainer
8.
Fuel rail
9.
O-ring (4) (included in hardware and o-ring kit)
10. Fuel injector (2)
11. Screw
12. Throttle cable bracket
13. Intake seal
14. Mounting flange
15. TMAP sensor
16. Screw, IAC (2)
Figure 4-52. Induction Module
ASSEMBLY
1.
. Install the following assemblies:
a.
TP Sensor. See
b.
TMAP sensor. See
ABSOLUTE PRESSURE (TMAP) SENSOR
c.
IAC. See
.
NOTE
Do not install IAC mounting screw on throttle wheel side of
induction module until cable bracket is installed in the next
step. Install other IAC mounting screw but do not tighten at this
time.
2.
Install cable bracket (12) onto induction module. Apply
Loctite Threadlocker 243 (blue) to the threads of screw
(11). Install screw finger-tight. Then tighten both IAC
mounting screws to 60 in-lbs (6.8 Nm). Tighten screw
(11) to 60 in-lbs (6.8 Nm).
3.
Install fuel injectors, fuel rail and fuel hose. See
.
INSTALLATION
1.
Make sure the two left side mounting screws are installed
two or three turns into the heads.
2.
. Install mounting flanges (3) on induction
module with counterbore (1) facing toward the engine.
3.
Place a new seal (4) into each mounting flange with the
beveled edge (2) facing the mounting flange counterbore.
Rotate the flanges so the slotted mounting hole is on the
same side as the IAC solenoid.
NOTE
When induction module is positioned on manifold mounting
screws, be sure the flanges are installed correctly on the
manifold. Also be sure the rubber seals are in place.
4.
. Place induction module assembly in
position between engine heads. Slide open slotted ends
of mounting flanges under heads of two mounting screws
on left side of engine.
5.
While holding induction module assembly in place, install
two mounting screws (3) into remaining mounting flange
holes. Tighten all four screws finger-tight.
6.
Tighten all four mounting screws to 96-120 in-lbs (10.9-
13.6 Nm).
7.
Inspect o-rings on flare fittings (2) and replace as neces-
sary. Install flare fittings in cylinder heads and tighten to
22-26 ft-lbs (29.8-35.3 Nm).
8.
Connect oil line flare nuts (1) to flare fittings (2) and tighten
to 13-17 ft-lbs (17.6-23.0 Nm).
9.
Install throttle cables. See
10. Adjust throttle and idle cables. See
3
4
1
2
sm05423
1.
Beveled counterbore
2.
Beveled edge
3.
Mounting flange
4.
Tapered seal
Figure 4-53. Mounting Flange and Seal
11. California models only: See
. Install purge
hose onto fitting (8) on induction module (1).
4-36 2009 Sportster Service: Fuel System
12. Plug in the following connectors:
a.
Front fuel injector (3) connector [84],
b.
Rear fuel injector (4) connector [85],
c.
TMAP sensor (5) connector [80],
d.
IAC (6) connector [87],
NOTE
Apply Harley-Davidson Electrical Contact Lubricant part
number 99861-02 to the TPS connector and terminals
prior to connecting to TPS.
e.
TP sensor (7) connector [88].
13. See
. Install induction module cover. Secure
TP sensor harness to cover during installation using a new
cable tie with anchor. Install all fasteners finger tight before
final tightening any. Tighten socket head bolts (3) to 20-
24 ft-lbs (27.1-32.5 Nm). Tighten fastener (2) to 84-108
in-lbs (9.5-12.2 Nm). Tighten fastener (1) to 84-108 in-
lbs (9.5-12.2 Nm).
14. Install airbox. See
15. Install fuel tank. See
.
16. Fill fuel tank and carefully check for leaks around fuel
pump module and quick connector. See
.
17. Install main fuse and close left side cover. See
18. Turn key switch to ON and then back to OFF to reset idle
air control to park position.
19. Start vehicle and check for fuel leaks.
20. Road test vehicle.
2009 Sportster Service: Fuel System 4-37
4.12
IDLE AIR CONTROL (IAC)
GENERAL
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
See
. The Electronic Control Module (ECM) uses
the Idle Air Control (IAC) to control engine idle speed.
Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the IAC.
1
2
3
3
sm01628a
1.
Induction module: XL models
2.
Induction module: XR models
3.
IAC
Figure 4-54. Idle Air Control (IAC) Location (Induction
Module Removed From Vehicle for Clarity)
4-38 2009 Sportster Service: Fuel System
REMOVAL: XL MODELS
TOOL NAME
PART NUMBER
HEAT GUN
HD-25070
NOTE
It is not necessary to remove the fuel tank, induction module
or induction module mounting bracket in order to replace the
IAC.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Unplug main fuse. See
.
2.
Remove air cleaner cover, air filter element and backing
plate assembly. See
.
3.
See
. Unplug harness connector [87B] from
IAC connector [87A] (1).
NOTE
Screws (2) MUST be heated to soften the thread sealant and
avoid breakage during removal. Use ONLY HEAT GUN (Part
No. HD-25070) to heat the screws. NEVER use an open flame.
4.
Using a six-point socket (not a Torx wrench), remove two
screws (2) in the following order:
a.
Heat fastener nearest to throttle bracket for two
minutes using HEAT GUN (Part No. HD-25070).
Remove screw.
b.
Heat remaining screw for one minute and remove.
5.
. Grasp IAC and rotate clockwise until IAC
mounting tab (1) clears throttle cable bracket (2).
6.
With a gentle twisting motion, pull IAC straight out of
induction module body.
3
4
2
1
sm01629
1.
IAC Connector [87A]
2.
Screw (2)
3.
IAC
4.
Throttle cable bracket
Figure 4-55. IAC Removal/Installation (XL Models)
1
2
sm01630
1.
IAC mounting tab (2) (rotated 45 degrees)
2.
Throttle cable bracket
Figure 4-56. Removing/Installing IAC (XL Models)
INSTALLATION: XL MODELS
1.
See
. If re-using IAC (1), inspect o-ring (2) for
cuts, tears or signs of deterioration. Install new o-ring if
necessary.
2.
Clean all locking agent from the threads of the attachment
screws and holes. Blow debris from screw holes using
low-pressure compressed air.
3.
Apply a thin coat of clean engine oil to o-ring.
4.
Note orientation and position of IAC, shown in
Rotate IAC approximately 45 degrees clockwise from this
position (see
.) so IAC mounting tab will clear
throttle cable bracket (4) when IAC is installed.
5.
With a gentle twisting motion, insert IAC into induction
module.
6.
Rotate IAC so that harness connector faces intake mani-
fold and mounting tab is underneath tab on throttle cable
bracket.
7.
See
. Apply a drop of Loctite Threadlocker and
Sealant 243 (blue) the threads of each screw (2).
8.
Install two screws (2). Using a six-point socket (not a Torx
wrench), tighten to 60 in-lbs (6.8 Nm).
9.
Plug harness connector [87B] into IAC connector [87A]
(1).
10. Install air cleaner backing plate assembly, air filter element
and air cleaner cover. See
11. Install main fuse and close left side cover. See
12. Road test vehicle.
2009 Sportster Service: Fuel System 4-39
3
2
2
1
sm01632
1.
IAC
2.
O-ring
3.
Pintle
Figure 4-57. IAC and O-ring (All Models)
REMOVAL: XR MODELS
TOOL NAME
PART NUMBER
HEAT GUN
HD-25070
NOTE
It is not necessary to remove the fuel tank, airbox or induction
module from the vehicle in order to replace the IAC.
Gasoline can drain from quick-connect fitting when
removing fuel line. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. Wipe up spilled fuel immediately and dispose of
rags in a suitable manner. (00267a)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Unplug main fuse. See
3.
. Unplug harness connector [87B] from
IAC connector [87A] (1).
NOTE
Screws (2) MUST be heated to soften the thread sealant and
avoid breakage during removal. Use ONLY HEAT GUN (Part
No. HD-25070) to heat the screws. NEVER use an open flame.
4.
Using a six-point socket (not a Torx wrench), remove two
screws (2) in the following order:
a.
Heat fastener nearest to throttle bracket for two
minutes using HEAT GUN (Part No. HD-25070).
Remove screw.
b.
Heat remaining screw for one minute and remove.
5.
See
. Grasp IAC and rotate counterclockwise
until IAC mounting tab (1) clears throttle cable bracket (2).
6.
With a gentle twisting motion, pull IAC straight out of
induction module body.
1
2
3
4
sm04969
1.
IAC Connector [87A]
2.
Screw (2)
3.
IAC
4.
Throttle cable bracket
Figure 4-58. IAC Removal/Installation (XR Models)
4-40 2009 Sportster Service: Fuel System
1
2
sm04970
1.
IAC mounting tab (2) (rotated 45 degrees)
2.
Throttle cable bracket
Figure 4-59. Removing/Installing IAC (XR Models)
INSTALLATION: XR MODELS
1.
. If re-using IAC (1), inspect o-ring (2) for
cuts, tears or signs of deterioration. If necessary, replace
with new o-ring.
2.
Clean all locking agent from the threads of the attachment
screws and holes. Blow debris from screw holes using
low-pressure compressed air.
3.
Apply a thin coat of clean engine oil to o-ring.
4.
Note orientation and position of IAC, shown in
Rotate IAC approximately 45 degrees counterclockwise
from this position (see
.) so IAC mounting tab
will clear throttle cable bracket (4) when IAC is installed.
5.
With a gentle twisting motion, insert IAC into induction
module.
6.
Rotate IAC so that harness connector points straight down
and mounting tab is underneath tab on throttle cable
bracket.
7.
See
. Apply a drop of Loctite Threadlocker and
Sealant 243 (blue) the threads of each screw (2).
8.
See
. Install two screws (2). Using a six-point
socket (not a TORX wrench), tighten to 60 in-lbs (6.8 Nm).
9.
Plug harness connector [87B] into IAC connector [87A]
(1).
10. Connect fuel hose to fuel pump module. Fill fuel tank with
gasoline. See
.
11. Plug in main fuse and close left side cover. See
12. Turn on ignition switch and start vehicle. Carefully check
for leaks around fuel hose fitting.
13. Road test vehicle.
2009 Sportster Service: Fuel System 4-41
4.13
TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR
GENERAL
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
. The Temperature Manifold Absolute Pressure
(TMAP) sensor (1) performs the dual functions of monitoring
air temperature and air pressure in the intake manifold.
Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the TMAP sensor.
2
1
1
3
5
4
sm01622
1.
TMAP sensor
2.
Screw (2) (XL only)
3.
Screw (XR only)
4.
Induction module/intake manifold: XL models
5.
Induction module: XR models
Figure 4-60. TMAP Sensor Location (Induction Module
Removed From Vehicle for Clarity)
REMOVAL: XL MODELS
NOTE
It is not necessary to remove the fuel tank from the vehicle in
order to replace the TMAP sensor.
4-42 2009 Sportster Service: Fuel System
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
Gasoline can drain from quick-connect fitting when
removing fuel line. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. Wipe up spilled fuel immediately and dispose of
rags in a suitable manner. (00267a)
1.
Unplug main fuse. See
.
2.
Remove air cleaner cover, air filter element and backing
plate assembly. See
.
3.
Remove fuel rail and fuel injectors. See
. This will allow access to the two screws that
secure the induction module to the intake manifold.
4.
See
. Remove two screws (2) and separate
induction module from intake manifold. See
.
5.
. Pull induction module away from intake
manifold far enough so that TMAP sensor retaining bracket
(1) clears TMAP sensor body (2).
6.
Unplug harness connector [80B] from TMAP connector
[80A] (3).
7.
Grasp TMAP sensor and with a gentle twisting motion,
pull sensor straight up out of intake manifold body.
3
4
1
2
sm01623
1.
TMAP sensor retaining bracket
2.
TMAP sensor
3.
Sensor connector [80A]
4.
O-ring
Figure 4-61.TMAP Sensor Removal/Installation (Induction
Module Removed From Vehicle for Clarity)
INSTALLATION: XL MODELS
1.
See
. If re-using TMAP sensor (1), inspect o-
ring (2) in groove of sensor for cuts, tears or signs of
deterioration. Install new o-ring if necessary.
2.
Apply a thin coat of clean engine oil to TMAP sensor o-
ring.
3.
. With a gentle twisting motion, insert
sensor (2) into intake manifold with connector [80A] (3)
facing rear cylinder head.
4.
Plug harness connector [80B] into TMAP sensor.
5.
Examine o-ring (4) between induction module and intake
manifold for cuts, tears or signs of deterioration. Install
new o-ring if necessary. Make certain o-ring is fully seated
in its grove in induction module body.
6.
See
. Mate induction module to intake manifold
and secure with two screws (2) Tighten to 35 in-lbs (4.0
Nm).
7.
Install fuel injectors and fuel rail. See
8.
Install air cleaner backing plate assembly, air filter element
and air cleaner cover. See
To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)
Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)
Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)
9.
Connect fuel hose to fuel pump module. Fill fuel tank and
carefully check for leaks around fuel pump module. See
4.6 FUEL TANK: XL MODELS, Reconnecting Fuel Hose
and Filling Fuel Tank
10. Install main fuse and close left side cover. See
2009 Sportster Service: Fuel System 4-43
1
2
sm01624
1.
TMAP sensor
2.
O-ring
Figure 4-62. TMAP Sensor
REMOVAL: XR MODELS
NOTE
It is not necessary to remove the fuel tank, airbox or induction
module from the vehicle in order to replace the TMAP sensor.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Unplug main fuse. See
.
NOTE
.TMAP sensor harness and TP sensor harness
are attached to inside of induction module cover (1). It is not
necessary to remove the retainer securing these harnesses to
the induction module cover in order to access TMAP sensor.
2.
. Remove socket head bolts (3), fastener
(1) and fastener (2).
3.
. Carefully rotate induction module cover
(1) out of the way.
4.
Unplug TMAP sensor harness connector [80B] (2).
Remove screw (4).
5.
Grasp TMAP sensor (3) and with a gentle twisting motion,
pull sensor straight up out of induction module body.
3
1
2
sm05419
1.
Fastener, wire form
2.
Fastener, to induction module
3.
Socket head bolts (2)
Figure 4-63. Induction Module Cover
1
3
2
4
sm04966
1.
Induction module cover
2.
Sensor harness connector [80B]
3.
TMAP sensor [80A]
4.
Screw
Figure 4-64. TMAP Sensor: XR Models (airbox removed
for clarity of photo)
INSTALLATION: XR MODELS
1.
See
. If re-using TMAP sensor (1), inspect o-
ring (2) for cuts, tears or signs of deterioration. If neces-
sary, replace with new o-ring.
2.
Apply a thin coat of clean engine oil to TMAP sensor o-
ring.
3.
. With a gentle twisting motion, insert
sensor (3) into induction module with connector [80A]
pointing down. Secure sensor to induction module with
screw (4). Tighten to 60 in-lbs (6.8 Nm).
4.
Plug sensor harness connector [80B] (2) into TMAP
sensor.
NOTE
Install all fasteners finger tight before final tightening any.
4-44 2009 Sportster Service: Fuel System
5.
. Rotate induction module cover into place
between cylinder heads. Install fasteners (1, 2, 3) finger
tight.
6.
Tighten socket head bolts (3) to 20-24 ft-lbs (27.1-32.5
Nm). Tighten fastener (2) to 84-108 in-lbs (9.5-12.2 Nm).
Tighten fastener (1) to 84-108 in-lbs (9.5-12.2 Nm).
7.
Plug in main fuse. See
.
2009 Sportster Service: Fuel System 4-45
4.14
OXYGEN SENSOR
GENERAL
NOTE
Photographs of XL models will be used throughout this process.
Although the exact location of the O2 sensors vary slightly
between XL models and XR models, replacement procedures
are essentially the same. For ease of installation, note harness
routing prior to removal.
. The oxygen (O2) sensors are installed in
threaded bosses on the inboard side of front and rear exhaust
pipes.
NOTE
Both Oxygen sensors are identical. However, if they will be
reused, it is best to mark them FRONT or REAR and return
each to the exhaust pipe in which it was originally mounted.
Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the O2 sensors.
1
2
sm01642
1.
Front oxygen sensor
2.
Rear oxygen sensor
Figure 4-65. Oxygen Sensor Locations, typical (XL model
shown)
REMOVAL
TOOL NAME
PART NUMBER
OXYGEN SENSOR SOCKET
HD-48262
OXYGEN SENSOR SOCKET
HD-48647
1.
Unplug sensor connector:
a.
Front O2 sensor: see
. Remove frame
clip (2). Unplug sensor connector [138A] (3) from
wiring harness connector [138B].
b.
Rear O2 sensor: see
. Disengage con-
nector [137] (2) from mounting tab. Unplug connector
[137A] from wiring harness connector [137B].
2.
Using the appropriate tool, remove sensor from mounting
boss on exhaust pipe. If reusing sensor, be careful not to
damage sensor harness.
a.
XL Models: OXYGEN SENSOR SOCKET (Part
No. HD-48262).
b.
XR Models: OXYGEN SENSOR SOCKET (Part
No. HD-48647).
1
2
3
sm01643
1.
Front oxygen sensor
2.
Frame clip
3.
Sensor connector [138]
Figure 4-66. Front Oxygen Sensor and Connector, typical
(XL model shown)
4-46 2009 Sportster Service: Fuel System
1
2
sm01644
1.
Rear oxygen sensor
2.
Sensor connector [137]
Figure 4-67. Rear Oxygen Sensor and Connector, typical
(XL model shown)
INSTALLATION
NOTES
•
Do not install sensors that have been dropped or impacted
by other components. Damage to the sensor element may
have occurred. Replacement sensor assemblies have
threads coated with anti-seize lubricant and new seal rings.
•
Apply a thin coat of anti-seize to threads of each oxygen
sensor prior to installing in header. Do not use any other
grease or sealant product on sensor threads. The electrical
connector must also be clean and free of any dielectric
grease.
1.
If sensor is being reused, install new seal ring and coat
sensor threads with anti-seize.
2.
Install sensor into threaded boss on exhaust pipe and
tighten to 29-44 ft-lbs (39.3-59.7 Nm).
3.
Route sensor harness to mating connector and connect:
a.
Front O2 sensor: see
. Plug sensor
connector [138A] (3) into wiring harness connector
[138B]. Install frame clip (2) over sensor harness,
clutch cable and wiring harness on left frame down-
tube.
b.
Rear O2 sensor: see
. Plug connector
[137A] (2) into wiring harness connector [137B].
Engage connector assembly onto mounting tab on
bracket.
NOTE
Route rear O2 sensor harness in a loop away from exhaust
system, toward left side of vehicle (as shown in the photo) to
avoid contact with exhaust port or exhaust pipe.
2009 Sportster Service: Fuel System 4-47
4.15
EXHAUST SYSTEM: XL MODELS
GENERAL
TOOL NAME
PART NUMBER
SNAP-ON WRENCH
PFSX916
To facilitate removing exhaust pipe header nuts, use SNAP-
ON WRENCH (Part No. PFSX916).
25
26
21
20
23
2
1
16
17
18
15
14
6
15
19
16
3
11
10
9
8
7
29
27
24
28
29
22
12
13
13
30
15
14
6
15
5
4
31
sm02198
23.
12.
1.
Screw
Heat shield, rear exhaust pipe
Muffler, front
2.
24.
13.
Muffler, rear
Engine sprocket cover
Worm drive clamp (5)
14.
3.
25.
Muffler heat shield (2) (Cali-
fornia, HDI, England only)
Exhaust pipe, front
Screw
26.
4.
Washer
Exhaust pipe, rear
15.
5.
27.
Worm drive clamp (4)
Muffler interconnect bracket
Front O2 sensor assembly
28.
16.
6.
Rear O2 sensor assembly
Flanged bolt (4)
Torca muffler clamp assembly
(2)
29.
17.
Seal ring (2)
Screw (3)
7.
18.
Exhaust port gasket (2)
30.
Washer (3)
O2 sensor connectors (2):
[137], [138]
19.
8.
Muffler interconnect gasket (2)
Exhaust gasket retaining ring
(2)
31. Heat shield, rear exhaust pipe
(mid-control vehicles only)
20. Exhaust pipe clamp
9.
21.
Exhaust pipe flange (2)
Exhaust pipe clamp bracket
22.
10.
Acorn nut
Nut (4)
11. Heat shield, front exhaust
pipe
Figure 4-68. Exhaust System, All XL Models
4-48 2009 Sportster Service: Fuel System
REMOVAL
Mufflers and Exhaust Pipes
NOTE
See
. Vehicles with mid controls are equipped with
an extra heat shield (2) on the rear exhaust pipe.
1.
. Remove heat shields:
a.
Vehicles with mid controls: remove worm drive
clamps (13) from heat shield (12) completely. Remove
bottom heat shield.
b.
All vehicles: open worm drive clamps (13) and
remove exhaust pipe heat shields (11, 12).
c.
California, HDI and England models: open worm
drive clamps (15) and remove muffler heat shields
(14).
2.
Unplug O2 sensor connectors (30). Front connector [138]
is mounted on left front frame downtube. Rear connector
[137] is attached to H-bracket behind engine on right side
of vehicle.
3.
Remove nuts (10) from front and rear cylinder head
exhaust studs.
4.
Remove flanged bolts (16) securing front and rear mufflers
(1, 2) to muffler interconnect bracket (5).
5.
Loosen Torca muffler clamp assemblies (6) on front and
rear mufflers. Remove mufflers. Discard muffler intercon-
nect gaskets (19).
6.
Remove and discard Torca clamp assemblies; they are
one time usage only.
NOTE
New Torca muffler clamps have eliminated the need for silicone
or graphite tape during assembly. To ensure sealing integrity
of muffler clamps and prevent the possibility of leakage, Harley-
Davidson recommends that torca muffler clamp assemblies
be discarded and replaced each time they are removed.
7.
Remove nut (22) and screw (23) from exhaust pipe clamp
(20). Separate exhaust pipe clamp from clamp bracket
(21).
8.
Remove front and rear exhaust pipes (3, 4). Slide exhaust
pipe clamp off rear exhaust pipe.
9.
Remove exhaust port gasket (7), retaining ring (8) and
exhaust pipe flange (9) from each exhaust pipe. Discard
gasket.
10. Remove O2 sensor assemblies (27, 28) from front and
rear exhaust pipes. Discard gaskets (29). See
.
1
2
3
4
sm04380
1.
Top heat shield
2.
Bottom heat shield
3.
Upper worm drive clamp
4.
Lower worm drive clamp
Figure 4-69. Rear Exhaust Pipe Heat Shields:Vehicles with
Mid Controls
Muffler Interconnect Bracket
1.
. Remove screw (6), washer (5) and
exhaust pipe clamp bracket (4). Remove two screws (2,
3). Remove sprocket cover (1).
2.
See
. Remove rear brake rod (1) at bell crank
(2).
3.
. Remove three screws (17) and washers
(18) securing muffler interconnect bracket (5) to engine
crankcase. Remove muffler interconnect bracket.
2
4
5
6
3
1
sm02202
1.
Sprocket cover
2.
Screw
3.
Screw
4.
Exhaust pipe clamp bracket
5.
Washer
6.
Screw
Figure 4-70. Sprocket Cover
2009 Sportster Service: Fuel System 4-49
1
5
4
3
2
sm02199
1.
Rear brake rod
2.
Bell crank
3.
Rear brake master cylinder assembly
4.
Rear brake pedal
5.
Frame
Figure 4-71. Rear Brake Linkage
INSTALLATION
TOOL NAME
PART NUMBER
SNAP-ON SWIVEL BALL SOCKET
EXTENSION
PFSX916
Muffler Interconnect Bracket
1.
See
. Install muffler interconnect bracket (5)
to engine case with three screws (17) and washers (18).
Tighten to 30-33 ft-lbs (40.7-44.8 Nm).
2.
. Apply two drops of LOCTITE 243 (Part.
No. 99642-97) to rear brake rod ball stud screw. Attach
rear brake rod (1) to bell crank (2). Tighten screw to 120-
180 in-lbs (13.6-20.4 Nm).
3.
See
. Install sprocket cover (1). Secure with
two screws (2, 3). Note that long screw goes in top hole,
short screw in bottom hole. Do not tighten screws at this
time.
4.
Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).
Exhaust Pipes and Mufflers
NOTES
•
To facilitate installing exhaust pipe header nuts, use
SNAP-ON SWIVEL BALL SOCKET EXTENSION (Part
No. PFSX916).
•
If the O2 sensors are being reused, apply a thin coat of
anti-seize to threads of each sensor prior to installing in
header. Do not use any other grease or sealant product
on sensor threads. The electrical connector must also be
clean and free of any dielectric grease.
1.
. If the front and rear O2 sensor assem-
blies (27, 28) are being reused, install new seal rings (29)
onto each sensor. Apply a thin coat of anti-seize to the
sensor threads.
2.
Install sensor assemblies into front and rear exhaust pipes.
Tighten to 29-44 ft-lbs (39.3-59.7 Nm). See
3.
Place exhaust pipe flange (9), exhaust gasket retaining
ring (8) and new exhaust port gasket (7) over front end of
each exhaust pipe (3, 4). Position flange so that inside
counterbore faces cylinder head exhaust port.
4.
Position front ends of front and rear exhaust pipes into
front and rear cylinder heads, respectively. Position holes
in flanges over mounting studs and loosely install nuts
(10). Do not tighten nuts at this time.
5.
Install exhaust pipe clamp (20) on rear exhaust pipe (4)
with square hole facing down. Assemble exhaust pipe
clamp to exhaust pipe clamp bracket (21) with screw (23)
and acorn nut (22). Make sure bracket fits between ends
of clamp. Do not tighten at this time.
6.
Install new muffler interconnect gaskets (19) in intercon-
nect mating holes in mufflers (1, 2).
7.
Place new Torca clamp assemblies (6) over slotted end
of each muffler. Install each muffler onto the end of its
respective exhaust pipe.
8.
Rotate both mufflers until their mounting bosses line up
with holes in muffler interconnect bracket. Carefully mate
each muffler with exhaust port in interconnect bracket.
Loosely install flanged bolts (16). Do not tighten at this
time.
9.
Tighten exhaust system fasteners in the following
sequence:
a.
Tighten four flanged bolts securing mufflers to inter-
connect bracket to 15-19 ft-lbs (20.4-25.8 Nm).
b.
Tighten four nuts at cylinder head exhaust studs to
96-120 in-lbs (10.9-13.6 Nm).
c.
Tighten two Torca clamps to 38-43 ft-lbs (51.6-58.4
Nm).
d.
Tighten rear exhaust pipe clamp nut (22) to 15-19 ft-
lbs (20.4-25.8 Nm).
10. Plug in O2 sensor connectors (30). Front connector [138]
is mounted on left front frame downtube. Rear connector
[137] is attached to H-bracket behind engine on right side
of vehicle. See
4-50 2009 Sportster Service: Fuel System
11. Install heat shields:
a.
Open worm drive clamps (13) and install heat shields
(11, 12) on exhaust pipes. Position each clamp so
that screw is on the outboard side in the most
accessible position.
b.
Vehicles with mid controls: See
.
Tighten lower worm drive clamp (4) a few turns. Slide
lower portion of bottom heat shield (2) into lower worm
drive clamp. Engage upper portion of bottom heat
shield into upper worm drive clamp (3).
c.
All vehicles: Tighten all exhaust pipe heat shield
clamps securely.
d.
California, HDI and England models: open worm
drive clamps (15) and install muffler heat shields (14)
on mufflers. Position each clamp so that screw is on
the outboard side in the most accessible position.
Tighten clamps securely.
2009 Sportster Service: Fuel System 4-51
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