Fastener torque values (Harley Sportster XL1200)

0

The table below lists torque values for all fasteners presented in this chapter.

FASTENER	TORQUE VALUE		Notes
Axle, rear, nut	95-105 ft·lbs	129-142 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Axle, rear, nut	95-105 ft·lbs	129-142 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Brake hose clamp to frame, rear, screw	30-40 in·lbs	3.4-4.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Brake master cylinder reservoir, rear, mounting screw	20-25 in·lbs	2.3-2.8 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Breather screw: XL Models	35-55 in·lbs	4.0-6.2 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Rocker Covers
Checkvalve housing fastener: XR 1200X	90-120 in·lbs	10.3-13.6 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Cylinder Head Oil Feed Assembly
Checkvalve housing fastener: XR 1200X	90-120 in·lbs	10.3-13.6 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Cam Gears and Gearcase Cover: XR 1200X
Checkvalve plug fitting: XR 1200X	15-21 ft·lbs	20.3-28.5 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Cylinder Head Oil Feed Assembly
Crankcase fastener	15-19 ft·lbs	20.3-25.8 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Crankcase
Cylinder headbolts, 1st torque	96-120 in·lbs	11-14 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder Head/See procedure
Cylinder headbolts, 1st torque	96-120 in·lbs	11-14 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder Head/See procedure
Cylinder headbolts, final torque	13-15 ft·lbs	18-20 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder Head/Plus 90 degrees. See procedure
Cylinder headbolts, final torque	13-15 ft·lbs	18-20 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Cylinder Head/Plus 90 degrees. See procedure
Cylinder head oil feed flare fitting: XR 1200X	22-26 ft·lbs	29.8-35.3 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Cylinder Head Oil Feed Assembly/Apply LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (blue)
Cylinder head oil feed line flare nut: XR 1200X	13-17 ft·lbs	18-23 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Cylinder Head Oil Feed Assembly
Cylinder stud	120-240 in·lbs	13.6-27.1 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Crankcase
Engine mount, front, bolt	95-105 ft·lbs	129-142 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Engine mount, front, bolt	95-105 ft·lbs	129-142 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Exhaust pipe clamp bracket screw	30-33 ft·lbs	40.7-44.8 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Footrest mount fastener	45-50 ft·lbs	61.0-67.8 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Footrest mount fastener	45-50 ft·lbs	61.0-67.8 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Footrest mount fastener	45-50 ft·lbs	61.0-67.8 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Fork, rear, pivot/engine mount bolt	60-70 ft·lbs	81.4-95.0 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Fork, rear, pivot/engine mount bolt	60-70 ft·lbs	81.4-95.0 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Fuel tank mounting screw	15-20 ft·lbs	20.4-27.1 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Fuel tank mounting screw	15-20 ft·lbs	20.4-27.1 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Fuel tank mounting screw	15-20 ft·lbs	20.4-27.1 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Assembling Motorcycle After Top End Repair
Gearcase cover fastener	90-120 in·lbs	10.2-13.6 Nm	3.21 OIL PUMP: XR 1200X, Assembly
Gearcase cover fastener	90-120 in·lbs	10.2-13.6 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Cam Gears and Gearcase Cover: XL Models
Gearcase cover fastener	90-120 in·lbs	10.2-13.6 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Cam Gears and Gearcase Cover: XR 1200X
Gearcase cover fastener	90-120 in·lbs	10.2-13.6 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Cam Gears and Gearcase Cover: XR 1200X
Gearcase housing plug	108-156 in·lbs	12.2-17.6 Nm	3.21 OIL PUMP: XR 1200X, Assembly
Ignition switch mounting screw	34-45 in·lbs	4.0-5.1 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Ignition switch mounting screw	34-45 in·lbs	4.0-5.1 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Induction module coverto cylinder head fastener: XR 1200X	20-24 ft·lbs	27.1-32.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Induction module coverto induction module fastener: XR 1200X	84-108 in·lbs	9.5-12.2 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Induction module coverto wire form fastener: XR 1200X	84-108 in·lbs	9.5-12.2 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Isolator mount, front, screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Isolator mount, front, screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Isolator mount, rear, screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Isolator mount, rear, screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Oil cooler fastener: XR 1200X	36-60 in·lbs	4.1-6.8 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X/Apply LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (blue)
Oil cooler fastener: XR 1200X	36-60 in·lbs	4.1-6.8 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Oil Cooler/Apply LOCTITE 243 MEDIUM STRENGHT THREADLOCKER AND SEALANT (blue)
Oil deflector plate screw: XR 1200X	38-48 in·lbs	4.3-5.4 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Crankcase
Oil filter adapter	18-22 ft·lbs	24.4-29.8 Nm	3.23 OIL FILTER MOUNT, Assembly
Oil line quick connect fitting, cylinder head return: XR 1200X	108-156 in·lbs	12.2-17.6 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Cylinder Head Oil Return Lines
Oil line retainer, front, nut: XR 1200X	84-108 in·lbs	9.5-12.2 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Cylinder Head Oil Return Lines
Oil pump cover screws	70-80 in·lbs	7.9-9.0 Nm	3.20 OIL PUMP: XL MODELS, Assembly
Oil pump feed fitting	100-120 in·lbs	11.3-13.6 Nm	3.20 OIL PUMP: XL MODELS, Installation
Oil pump high pressure feed hose fitting nut	85-105 in·lbs	9.6-11.8 Nm	3.20 OIL PUMP: XL MODELS, Installation
Oil pump high pressure feed hose to crankcase fitting	60-90 in·lbs	6.8-10.2 Nm	3.20 OIL PUMP: XL MODELS, Installation
Oil pump quick connect fitting: XR 1200X	108-156 in·lbs	12.2-17.6 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Oil Pump Lines
Oil pump rotor cover screw: XR 1200X	90-120 in·lbs	10.2-13.6 Nm	3.21 OIL PUMP: XR 1200X, Assembly
Oil pump rotor cover screw: XR 1200X	90-120 in·lbs	10.2-13.6 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Cam Gears and Gearcase Cover: XR 1200X
Oil pump to crankcase screw	125-150 in·lbs	14.1-16.9 Nm	3.20 OIL PUMP: XL MODELS, Installation
Oil rigid line retainer, rear, screw: XR 1200X	84-108 in·lbs	9.5-12.2 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Cylinder Head Oil Return Lines
Oil rigid line retainer, rear, screw: XR 1200X	90-120 in·lbs	10.2-13.6 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Oil Pump Lines
Oil tank mounting screw	36-60 in·lbs	4.1-6.8 Nm	3.24 OIL TANK, Installation
Pinion shaft locking nut: XR 1200X	19-21 ft·lbs	26-29 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Cam Gears and Gearcase Cover: XL Models/ plus an additional 15-19 degrees of rotation
Pinion shaft locking nut: XR 1200X	19-21 ft·lbs	26-29 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Cam Gears and Gearcase Cover: XR 1200X/ plus 15-19 degrees of rotation
Piston oil jet screw	38-48 in·lbs	4.3-5.4 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Crankcase
Retainer plate, lower front, fastener	45-50 ft·lbs	61.0-67.8 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Return oil manifold screw: XR 1200X	84-108 in·lbs	9.5-12.2 Nm	3.12 PRECISION COOLING SYSTEM: XR 1200X, Return Oil Manifold
Rocker cover, inner, large bolt	18-22 ft·lbs	24.4-29.8 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Rocker Covers
Rocker cover, inner, screw	135-155 in·lbs	15.3-17.5 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Rocker Covers
Rocker cover, inner, small bolt	135-155 in·lbs	15.3-17.5 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Rocker Covers
Rocker cover, outer, screw	120-168 in·lbs	13.5-19.0 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Rocker Covers
Shift linkage pivot bolt	120-180 in·lbs	13.6-20.3 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Shock absorber mounting bolt	45-50 ft·lbs	61.0-67.8 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Siren/canister bracket rear brake line fastener	17-22 ft·lbs	23.0-29.8 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Sprocket cover, forward and lower screws	80-120 in·lbs	9.0-13.6 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Sprocket cover, forward and lower screws	80-120 in·lbs	9.0-13.6 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Sprocket cover, rear screw	30-33 ft·lbs	40.7-44.8 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Stabilizer link, lower, frame bracket, front, mounting screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Stabilizer link, lower, frame bracket mounting screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Stabilizer link, lower front, frame bracket mounting screw	25-35 ft·lbs	33.9-47.5 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Assembling Motorcycle After Top End Repair
Stabilizer link, upper front, frame bracket mounting screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Stabilizer link, upper front, frame bracket mounting screw	25-35 ft·lbs	33.9-47.5 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Assembling Motorcycle After Top End Repair
Stabilizer link cylinder head bracket	55-65 ft·lbs	74.6-88.2 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Stabilizer link cylinder head bracket	55-65 ft·lbs	74.6-88.2 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Stabilizer link screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Stabilizer link screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Stabilizer link screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Stabilizer link screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Stabilizer link screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Stabilizer link screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Stabilizer link screw	25-35 ft·lbs	33.9-47.5 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XR 1200X
Stop lamp switch bracket screw	72-120 in·lbs	8.1-13.6 Nm	3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models
Tappet cover, anti-rotation mounting screw	90-120 in·lbs	10.2-13.6 Nm	3.22 BOTTOM END OVERHAUL: ASSEMBLY, Tappets
Tappet cover fastener	90-120 in·lbs	10.2-13.6 Nm	3.16 TOP END OVERHAUL: ASSEMBLY, Tappet Covers, Pushrod Covers and Pushrods

See this article in russian language

Article about repair motorcycles «Harley Sportster XL1200» (2012-2023): «Fastener torque values»: https://motoinstruction.ru/en/Harley/Sportster/XL_2012/engine/repair/113025 <a href="https://motoinstruction.ru/en/Harley/Sportster/XL_2012/engine/repair/113025">Fastener torque values</a> - article about repair motorcycles «Harley Sportster XL1200» (2012-2023) from section «Engine repair». [url=https://motoinstruction.ru/en/Harley/Sportster/XL_2012/engine/repair/113025]Fastener torque values[/url] - article about repair motorcycles «Harley Sportster XL1200» (2012-2023) from section «Engine repair».