Harley Davidson Sportster Models 2009. Service Repair Manual — page 30
REMOVAL
NOTE
The oil pump can be removed with engine in frame and without
removing gearcase cover.
1.
Drain oil from oil tank.
NOTE
See
. Do not remove oil pump feed fitting (2) from
the pump (1). Hold oil pump feed fitting and loosen large high
pressure hose fitting nut (3). Then remove high pressure hose
(4) from oil pump feed fitting.
2.
. Remove high pressure feed hose (4)
from oil pump (1).
1
2
3
4
sm01486
1.
Oil pump
2.
Oil pump feed fitting
3.
High pressure hose fitting nut
4.
High pressure feed hose (to oil filter)
Figure 3-166. Oil Pump Feed Hose
NOTE
See
. The oil pump is designed to be removed as
a complete assembly by removing the two long screws (2) at
opposite corners of the pump. The other two screws (3) hold
the pump together so that it may be removed and installed as
a unit.
3.
. Carefully remove two screws (2) that
secure oil pump to crankcase. Pump will drop with screws
removed. Discard mounting gasket (15).
4.
Disconnect and tag the two remaining oil hoses from the
pump.
DISASSEMBLY
1.
See
. Remove two Torx screws (3). Lift cover
(1) off body (12). Remove and discard o-ring (11).
2.
Slide both pieces of feed gerotor set (6), separator plate
(7) and both pieces of scavenge gerotor set (8) off gear
shaft (14).
3.
Remove and discard retaining ring (9). Remove thrust
washer (10) and gear shaft.
CLEANING AND INSPECTION
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Clean all parts in cleaning solvent. Blow out holes and oil
passages with compressed air.
2.
See
. Inspect both gerotor sets for wear.
a.
Mesh pieces of each set together as shown.
b.
Use a feeler gauge to determine clearance.
c.
The SERVICE WEAR LIMIT between gerotors is
0.004 in. (0.102 mm). Replace gerotors as a set if
clearance exceeds this dimension.
d.
Measure thickness of feed gerotors with a micrometer.
Replace gerotors as a set if they are not the same
thickness.
1
2
3
sm03409
1.
Outer gerotor
2.
Inner gerotor
3.
Wear limit
Figure 3-167. Gerotor Wear Limits
ASSEMBLY
NOTE
Liberally coat all moving parts with clean engine oil to ensure
easy assembly and smooth operation at start-up.
1.
. Install gear shaft (14) through oil pump
body (12). Position thrust washer (10) over end of shaft.
Install new retaining ring (9) into groove in shaft.
2.
Insert inner gerotor of the scavenge gerotor set (8) over
gear shaft.
3.
Place outer gerotor over inner to complete scavenge set.
4.
Position separator plate (7) into case and line up slots on
perimeter with tabs inside oil pump body.
5.
Place feed gerotor set (6) over gear shaft.
6.
Install a new o-ring (11) into groove in oil pump cover (1).
Place cover onto pump body. Install two Torx cover screws
(3). Tighten to 70-80 in-lbs (7.9-9.0 Nm).
2009 Sportster Service: Engine 3-131
INSTALLATION
1.
See
. Place new mounting gasket (15) in
position.
2.
Secure pump to crankcase with two screws (2). Tighten
to 125-150 in-lbs (14.1-16.9 Nm).
NOTE
Use new hose clamps to secure oil tank feed hose and vent
hose to oil pump fittings. If fittings were removed, use TEFLON
PIPE SEALANT or HYLOMAR on fitting threads.
3.
Install hoses on oil pump. Attach oil tank feed hose to hose
fitting (5) with new clamp. Attach oil tank vent hose to
elbow fitting (13) with new clamp.
4.
. If oil pump feed fitting (2) was removed
for any reason, install fitting in oil pump (1) cover. Tighten
to 55-65 in-lbs (6.2-7.4 Nm).
5.
If high pressure feed hose (4), was removed completely,
install end opposite high pressure fitting nut (3) in crank-
case. Tighten to 60-90 in-lbs (6.8-10.2 Nm).
6.
Install high pressure feed hose fitting nut (3) onto feed fit-
ting on front of oil pump. Hold oil pump feed fitting with a
wrench and tighten high pressure hose fitting nut to 85-
105 in-lbs (9.6-11.8 Nm).
7.
Fill oil tank with proper oil. See
3-132 2009 Sportster Service: Engine
3.25
OIL PUMP: XR MODELS
GENERAL
The oil pump seldom needs servicing. Before you disassemble
an oil pump suspected of not producing adequate oil pressure,
be sure that all possible related malfunctions have been elim-
inated.
1.
Make sure all oil line connections are tight and that lines
are not pinched or damaged.
2.
Check level and condition of oil in tank. Pressure will be
affected if oil is diluted. In freezing weather, proper circu-
lation of oil can be affected if the oil feed line becomes
clogged with ice or sludge.
3.
Check for a grounded oil pressure switch wire [120] or
faulty switch if oil pressure indicator light fails to go out
with engine running.
See
and
for additional information.
2009 Sportster Service: Engine 3-133
1
2
3
7
8
4
5
6
10
9
13
14
15
12
16
17
18
19
11
21
22
27
26
25
24
23
28
20
sm05382
21.
11.
1.
Line connector fitting, oil to
cooler
Oil pump/gearcase housing
Oil pump rotor cover
2.
12.
O-rings, rotor cover
O-ring
22.
13.
3.
Thermostat (oil from cooler)
Check valve housing, cylinder
head oil
Retainer
4.
23.
O-ring, internal (1 each fitting)
Plugs
14.
24.
O-ring
5.
Bypass valve shuttle
Line connector fitting, return
oil
25.
15.
Spring, bypass valve
Fastener (2)
6.
16.
O-ring, external (1 each fitting)
26.
Plug
O-ring
27.
17.
7.
Plug
O-ring
Scavenge gerotor set
8.
28.
18.
Feed gerotor set
Fastener (6)
Spring
19.
9.
Check ball
Line connector fitting, supply
oil
20. Gasket
10. Vent line fitting
Figure 3-168. Oil Pump: XR Models
DISASSEMBLY
NOTE
The oil pump can be removed with engine in frame and without
removing gearcase cover.
1.
Drain oil from oil tank.
2.
Place pan under oil pump to collect oil.
3.
See
. Remove nine fasteners (1) and remove
gearcase and oil pump cover (2).
4.
. Remove oil cooler rigid lines (3) from
gearcase cover. See
SYSTEM: XR MODELS, Oil Pump Lines
.
5.
Remove six screws (1) and remove oil pump cover (2).
Discard cover o-rings.
3-134 2009 Sportster Service: Engine
NOTE
If oil pump rotors are to be re-used, they must be installed in
the original location and orientation as when they are removed.
Failure to do so can result in accelerated wear and possible
engine failure.
6.
. Wipe the oil film from the exposed sur-
faces of the rotors (1, 2) and mark each rotor using a
permanent marker to aid in reassembly.
NOTE
The surface tension of the remaining oil film will make the rotors
"stick" against the bottom of the bore. Never use a metallic tool
to remove oil pump rotors because damage may result,
requiring that the rotors or gearcase cover be replaced with
new parts.
7.
Grasp the outer rotor (1) of each stage and pull from
housing bore.
8.
Remove each inner rotor (2).
9.
Remove the thermostat fitting (3) and spring.
10. Remove the plug and bypass valve components (4).
11. If necessary, remove remaining line connector fittings from
gearcase cover.
12. Remove and discard all used o-rings.
1
2
sm05003
1.
Fastener (9)
2.
Cover
Figure 3-169. Oil Pump Cover: XR Models
3
2
1
sm05018
1.
Oil pump cover screw (6)
2.
Oil pump rotor cover
3.
Oil cooler rigid lines
Figure 3-170. Oil Pump Rotor Cover: XR Models
1
2
4
3
sm05019
1.
Outer rotor
2.
Inner rotor
3.
Thermostat
4.
Bypass valve plug and components
Figure 3-171. Oil Pump: XR Models
CLEANING AND INSPECTION
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Clean all parts in cleaning solvent. Blow out holes and oil
passages with compressed air.
2009 Sportster Service: Engine 3-135
2.
. Inspect both gerotor sets for wear.
a.
Mesh pieces of each set together as shown.
b.
Use a feeler gauge to determine clearance.
c.
The SERVICE WEAR LIMIT between gerotors is
0.004 in. (0.102 mm). Replace gerotors as a set if
clearance exceeds this dimension.
d.
Measure thickness of feed gerotors with a micrometer.
Replace gerotors as a set if they are not the same
thickness.
3.
See
. Inspect thermostat spring for distortion
or cracks. Inspect rubber seal for damage. Replace ther-
mostat assembly as necessary.
1
2
3
sm03409
1.
Outer gerotor
2.
Inner gerotor
3.
Wear limit
Figure 3-172. Gerotor Wear Limits
sm05659
Figure 3-173. Thermostat: XR Models
ASSEMBLY
NOTE
Used o-rings can leak. Always install new o-rings when per-
forming repairs.
1.
Install new internal o-rings in each line connector fitting.
2.
Install new external o-rings on all connector fittings that
have been removed.
NOTE
Apply a light coat of new engine oil to the shuttle valve compon-
ents and oil pump rotors during assembly.
3.
See
. Install bypass valve components (4).
Tighten plug to 108-156 in-lbs (12.2-17.6 Nm).
4.
Install thermostat and oil cooler line fitting (3).
NOTE
If oil pump rotors are to be re-used, they must be installed in
the original location and orientation as when they were
removed. Make sure the mark made during disassembly is
visible when installing the rotors. Failure to do so can result in
accelerated wear and possible engine failure.
5.
Install each outer rotor (1) in its original location.
6.
Install each inner rotor (2) in its original location.
7.
. Install new o-rings in oil pump rotor
cover and install cover using six fasteners (1). Tighten
fasteners to 80-110 in-lbs (9.0-12.4 Nm).
8.
Install oil cooler rigid lines (3) to quick connect fittings. See
3.14 PRECISION COOLING SYSTEM: XR MODELS, Oil
Pump Lines
.
9.
See
. Install oil pump/cam support housing
cover. Secure with 9 socket fasteners. Tighten in the
sequence shown to 80-110 in-lbs (9.0-12.4 Nm).
7
3
1
5
4
2
6
8
9
sm05017
Figure 3-174. Oil Pump Cover Torque Sequence: XR Models
3-136 2009 Sportster Service: Engine
3.26
OIL FILTER MOUNT
GENERAL
Oil is pressure-fed from the oil pump to the oil filter mount via
a hose connection. Oil travels through the filter mount into the
filter via outer filter holes.
Adequate oil pressure activates the oil pressure indicator lamp
switch in the filter mount, which turns off the oil pressure
indicator lamp.
The check ball in the filter adapter opens at:
•
XL Models: 10-13 psi (69-90 kPa) oil pressure.
•
XR Models: 5-7 psi (34-48 kPa) oil pressure.
Filtered oil leaves the filter, flowing past the check ball.
DISASSEMBLY
1.
Remove oil filter. See
.
NOTE
The engine oil check valve components are located in the
Precision Cooling System cylinder head feed circuit. See
3.14 PRECISION COOLING SYSTEM: XR MODELS, Cylinder
Head Oil Feed Assembly
for service information.
2.
See
. Remove oil filter adapter (1) from oil
filter mount (2).
3.
Remove check ball (3) and spring (4).
4.
XL Models: Remove oil pressure indicator lamp switch
(5).
CLEANING AND INSPECTION
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
Thoroughly clean all parts in cleaning solvent. Blow out holes
and passages using compressed air.
ASSEMBLY
NOTE
Use TEFLON® PIPE SEALANT or HYLOMAR® on all fittings
installed to oil filter mount.
1.
. XL Models: Install oil pressure indicator
lamp switch (5). Tighten to 50-70 in-lbs (5.6-7.9 Nm).
2.
Place spring (4) and check ball (3) into threaded hole at
center of mount (2). Push oil filter adapter against ball to
compress spring.
NOTE
The new oil filter adapter has one end coated with pre-applied
LOCTITE on the threads; that end must be installed into the
oil filter mount.
3.
Install threaded end (with LOCTITE) into threaded hole at
center of mount. Tighten oil filter adapter to 96-144 in-lbs
(10.9-16.3 Nm).
4
3
1
2
2
1
5
sm03432
1.
Oil filter adapter
2.
Oil filter mount (part of right crankcase housing)
3.
Check ball
4.
Spring
5.
Oil pressure indicator lamp switch
Figure 3-175. Oil Filter Mount, Typical (XL model shown)
4.
Connect oil pressure switch wire [120] to oil pressure
indicator lamp switch.
5.
Install oil filter. Fill oil tank with proper oil. See
OIL AND FILTER, Changing Oil and Filter
.
2009 Sportster Service: Engine 3-137
3.27
OIL TANK
OIL HOSE ROUTING: XL MODELS
. The feed, vent and return ports are located
on the bottom of the oil tank to reduce under seat congestion
A hose routes the oil from the feed port at the lower right front
corner to a fitting on the oil pump.
From the feed section of the oil pump, another feed hose directs
the flow up to the oil filter mount. Eventually, oil drains to the
sump where it collects in the scavenge section of the oil pump.
The return hose routes the oil back to the tank where the cycle
is repeated.
5
4
3
2
1
Feed
Vent
Return
sm03423
1.
Filler cap and dipstick
2.
Oil tank
3.
Oil pump
4.
Oil filter
5.
Gear case cover
Figure 3-176. Engine Oil Tank, Oil Filter and Hose Routing Locations: XL Models
OIL LINE ROUTING: XR MODELS
. The feed, vent and return ports are located
on the bottom of the oil tank to reduce under seat congestion.
A hose routes the oil from the feed port at the lower right front
corner to a fitting on the oil pump.
Oil travels to the feed pump through an internal passage in the
pump housing. The feed pump pushes oil to the oil cooler, oil
filter, and cylinder heads. Oil used for lubricating internal engine
components eventually drains into the sump where the scav-
enge pump collects it and routes it back to the oil tank. Oil used
to cool the cylinder heads joins with return oil from the scav-
enge pump and is also returned to the oil tank. For a more
detailed explanation, see
.
3-138 2009 Sportster Service: Engine
2
1
5
7
4
3
6
9
9
8
10
10
10
9
8
2
12
11
1
3
5
4
sm05028
7.
1.
Cylinder head feed oil lines
Vent line
2.
8.
Return oil to tank
Front cylinder head return oil line
9.
3.
Oil from oil cooler
Supply oil from tank
4.
10.
Return oil manifold
Oil to oil cooler
11.
5.
Engine view, right side
Rear cylinder head return oil line
6.
12.
Return oil from pump
Engine view, left side
Figure 3-177. Engine Oil Line Routing: XR Models
2009 Sportster Service: Engine 3-139
REMOVAL
1.
Remove seat.
2.
Remove left side cover. See
Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)
3.
Disconnect negative (-) battery cable from ground stud on
crankcase. Disconnect positive (+) battery cables at bat-
tery. See
.
4.
Drain oil tank as follows (the oil filter need not be removed
unless it is due to be replaced):
a.
Remove filler cap/dipstick assembly from oil tank.
b.
. Place a suitable container directly
under the drain hose (1) at the bottom rear of the
engine crankcase. The container must be able to hold
approximately 4 quarts (3.8 liters).
c.
Loosen worm drive clamp (2) and pull drain plug (3)
from end of drain hose. Completely drain engine oil
from oil tank.
d.
Replace drain plug into end of drain hose and tighten
worm drive clamp securely.
5.
Remove right side cover by gently prying bottom lip off
tab on oil tank. Then lift top of cover off two stanchions
molded into top of oil tank.
6.
Remove rear belt guard. See
NOTE
For ease of assembly, mark oil tank hoses for identification;
oil feed, drain, vent and return, as they are removed from oil
tank.
7.
. Remove clamp (18) and disconnect
drain hose (9) from oil tank (1).
8.
Remove clamp (17) from upper end of feed oil hose (8)
and disconnect hose from oil tank.
9.
Remove clamp (16) from upper end of return oil hose (6)
and disconnect hose from oil tank.
10. Remove rear fender. See
,
LICENSE PLATE BRACKET: XL 1200N
or
11. See
. Remove clamp (16) from upper end of
vent oil hose (7) and disconnect hose from oil tank (1).
12. Remove three screws (5) and remove oil tank from right
side of motorcycle.
1
2
3
11763
1.
Oil tank drain hose
2.
Worm drive clamp
3.
Drain plug
Figure 3-178. Oil Tank Drain Hose
3-140 2009 Sportster Service: Engine
5
2
4
17
5
20
16
6
7
17
16
15
12
13
11
14
16
3
1
9
10
17
8
18
19
sm03424
11.
1.
Drain plug
Oil tank
2.
12.
O-ring
Hose clip
13.
3.
Clamp
Filler cap/dipstick
4.
14.
Screw
Lock nut
15.
5.
Elbow fitting
Oil tank mounting screw (3)
6.
16.
Return oil hose
Clamp (3)
17.
7.
Clamp (3)
Vent oil hose
8.
18.
Feed oil hose
Clamp
19.
9.
Oil drain hose sleeve
Drain oil hose
10.
20.
Worm drive clamp
Bracket
Figure 3-179. Engine Oil Tank Assembly: XL Models
2009 Sportster Service: Engine 3-141
INSTALLATION
NOTE
See
. The vent oil hose (7) is composed of a
flexible hose originating at the gearcase cover elbow fitting
(15), mated to a hard plastic line, then another flexible hose at
the oil tank vent fitting.
1.
. Slide oil tank (1) into position in frame
from right side of vehicle.
2.
Install oil tank mounting screw (5) through bracket (20)
and loosely screw into oil tank to hold tank in place. Install
remaining two mounting screws (5) through frame and
screw into oil tank. Tighten all three fasteners to 36-60 in-
lbs (4.1-6.8 Nm).
3.
Install marked oil vent hose (7), feed hose (8), drain hose
(9) and return hose (6) in their proper locations on oil tank
fittings. Secure with new clamps (16, 17, 18).
4.
Install rear fender. See
LICENSE PLATE BRACKET: XL 1200N
or
.
5.
Install rear belt guard. See
6.
Install right side cover.
a.
Engage two holes on top of cover onto stanchions on
top of oil tank.
b.
Rotate bottom end of cover downward until bottom
lip of cover snaps in place on tab on bottom of oil
tank.
7.
Fill oil tank and install filler cap/dipstick. See
OIL AND FILTER, Checking and Adding Oil
.
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
8.
Connect positive (+) battery cables to battery. Connect
negative (-) battery cable to ground point on engine
crankcase. See
.
9.
Install left side cover. See
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
10. Install seat.
3-142 2009 Sportster Service: Engine
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
FUEL SYSTEM
NOTES
4.1
FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
NOTES
TORQUE VALUE
FASTENER
4.4 AIR CLEANER: XL MODELS, Installation
13.6-16.3 Nm
120-144 in-lbs
Air cleaner breather screw
4.4 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
4.5-6.8 Nm
40-60 in-lbs
Air filter screw
4.15 EXHAUST SYSTEM: XL MODELS, Installation
13.6-20.4 Nm
120-180 in-lbs
Brake rod-to-bell crank screw
4.17 FUEL INJECTORS, Installation
23.1-32.6 Nm
17-24 ft-lbs
Cylinder head bracket screw
4.15 EXHAUST SYSTEM: XL MODELS, Installation
10.9-13.6 Nm
96-120 in-lbs
Cylinder head exhaust port nut
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
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
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
4.15 EXHAUST SYSTEM: XL MODELS, Installation
40.7-44.8 Nm
30-33 ft-lbs
Exhaust pipe clamp bracket screw
4.7 FUEL TANK: XR MODELS, Assemble Fuel
Tank
4.5-5.1 Nm
40-45 in-lbs
Filler housing screws
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
61.0-67.8 Nm
45-50 ft-lbs
Front muffler mount-to-frame fastener
4.17 FUEL INJECTORS, Installation
6.8 Nm
60 in-lbs
Fuel hose retaining bracket screw
4.18 FUEL PUMP, Assembly
2.1-4.1 Nm
19-36 in-lbs
Fuel pump/sender harness grounding
screw
4.18 FUEL PUMP, Assembly
2.1-4.1 Nm
19-36 in-lbs
Fuel pump bracket mounting screw
4.18 FUEL PUMP, Installation
4.5-5.1 Nm
40-45 in-lbs
Fuel pump module mounting screw
4.7 FUEL TANK: XR MODELS, Installing Fuel Tank
2.7-3.4 Nm
24-30 in-lbs
Fuel tank cover fastener
4.7 FUEL TANK: XR MODELS, Installing Fuel Tank
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank front fastener
4.6 FUEL TANK: XL MODELS, Installing Fuel Tank
20.4-27.1 Nm
15-20 ft-lbs
Fuel tank mounting screw
4.10 INDUCTION MODULE: XL MODELS, Install-
ation
20.4-27.1 Nm
15-20 ft-lbs
Fuel tank mounting screw
4.17 FUEL INJECTORS, Installation
20.4-27.1 Nm
15-20 ft-lbs
Fuel tank mounting screw
4.7 FUEL TANK: XR MODELS, Installing Fuel Tank
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank rear fastener
4.10 INDUCTION MODULE: XL
MODELS, Assembly
6.8 Nm
60 in-lbs
IAC mounting screw
2009 Sportster Service: Fuel System 4-1
NOTES
TORQUE VALUE
FASTENER
4.11 INDUCTION MODULE: XR
MODELS, Assembly
6.8 Nm
60 in-lbs
IAC mounting screw
4.12 IDLE AIR CONTROL (IAC), Installation: XL
Models
6.8 Nm
60 in-lbs
IAC mounting screw
4.12 IDLE AIR CONTROL (IAC), Installation: XR
Models
6.8 Nm
60 in-lbs
IAC mounting screw (XR models)
4.11 INDUCTION MODULE: XR
MODELS, Installation
27.1-32.5 Nm
20-24 ft-lbs
Induction module cover-to-cylinder head
fastener
4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models
27.1-32.5 Nm
20-24 ft-lbs
Induction module cover-to-cylinder head
fastener
4.11 INDUCTION MODULE: XR
MODELS, Installation
9.5-12.2 Nm
84-108 in-lbs
Induction module cover-to-induction
module fastener
4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models
9.5-12.2 Nm
84-108 in-lbs
Induction module cover-to-induction
module fastener
4.11 INDUCTION MODULE: XR
MODELS, Installation
9.5-12.2 Nm
84-108 in-lbs
Induction module cover-to-wire form
fastener
4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models
9.5-12.2 Nm
84-108 in-lbs
Induction module cover-to-wire form
fastener
4.10 INDUCTION MODULE: XL MODELS, Install-
ation
9.5-12.2 Nm
84-108 in-lbs
Induction module mounting bracket
screw
4.10 INDUCTION MODULE: XL
MODELS, Assembly
4.0 Nm
35 in-lbs
Induction module-to-intake manifold
screw
4.10 INDUCTION MODULE: XL
MODELS, Assembly
6.8 Nm
60 in-lbs
Induction module-to-intake manifold
screw
4.10 INDUCTION MODULE: XL MODELS, Install-
ation
10.9-13.6 Nm
96-120 in-lbs
Intake manifold mounting screw
4.11 INDUCTION MODULE: XR
MODELS, Installation
10.9-13.6 Nm
96-120 in-lbs
Intake manifold mounting screw
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
40.7-44.7 Nm
30-33 ft-lbs
Interconnect bracket-to-frame fastener
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
40.7-44.7 Nm
30-33 ft-lbs
Lower muffler mount nut
4.15 EXHAUST SYSTEM: XL MODELS, Installation
40.7-44.8 Nm
30-33 ft-lbs
Muffler interconnect bracket mounting
screw
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
16.9-20.3 Nm
120-180 in-lbs
Muffler-to-front muffler mount fastener
4.15 EXHAUST SYSTEM: XL MODELS, Installation
20.4-25.8 Nm
15-19 ft-lbs
Muffler-to-interconnect bracket screw
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
16.9-20.3 Nm
120-180 in-lbs
Muffler-to-muffler bolt
4.15 EXHAUST SYSTEM: XL MODELS, Installation
51.6-58.4 Nm
38-43 ft-lbs
Muffler torca clamp nut
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
16.9-20.3 Nm
120-180 in-lbs
Muffler-to-rear muffler mount fastener
4.15 EXHAUST SYSTEM: XL MODELS, Installation
39.3-59.7 Nm
29-44 ft-lbs
O2 sensor
4.14 OXYGEN SENSOR, Installation
39.3-59.7 Nm
29-44 ft-lbs
Oxygen sensor
4.16 EXHAUST SYSTEM: XR MODELS, Installa-
tion
20.3-27.1 Nm
15-20 ft-lbs
Rear muffler mount-to-frame fastener
4.15 EXHAUST SYSTEM: XL MODELS, Installation
9.0-13.6 Nm
80-120 in-lbs
Sprocket cover screw: XL models
4.11 INDUCTION MODULE: XR
MODELS, Assembly
6.8 Nm
60 in-lbs
Throttle cable bracket screw: XR models
4-2 2009 Sportster Service: Fuel System
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