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Dedicated Subsystem WorkbenchPlatform Gen: 2021–2026

2021 Harley Davidson Revolution Max 1250 / 1250T (Pan America / Sportster S) Valve Clearance Specs & Shim Calculator

Cold valve clearance specs for 2021 Harley Davidson Revolution Max 1250 / 1250T (Pan America / Sportster S): intake mm, exhaust mm, inspection intervals and replacement shim calculator.

Technical PassportOEM VERIFIED
Engine
1252cc
Cooling
Liquid-Cooled
Final Drive
525 Chain
Engine Oil
4.50 L (4.75 US qt)
Spark Plug
HD 6R10 / NGK LMAR9D-J
Front Tire
120/70R19 (Pan America) / 160/70R17 (Sportster S)
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Gen 2021–2026

Factory Platform Compatibility: All workshop fluid capacities, maintenance milestones, torque specifications, and consumables on this specification sheet are factory-identical across model years 2021 through 2026.

Select Model Year:(Active: 2021)
6 Production Years (2021–2026)
Suggested Items4 Verified Workshop Consumables Available for this Job
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Factory Valve Clearance & Shim Calculator

OEM Workshop Tolerances
Cylinder head valve lash specifications, timing TDC mark alignments, and interactive replacement shim calculation engine.
Adjustment Mechanism: Hydraulic Lash Adjusters (Self-Adjusting)
Active Valve Range (INTAKE)
0.00 mm (Zero Lash / Hydraulic Self-Adjusting)
0.000 in (Zero Lash Hydraulic)
Nominal Mid-Spec Target
0.15 mm
Ideal cold lash assembly setting
Shim Diameter / Tappet
Hydraulic Lash Adjusters (Self-Adjusting)
Bucket-and-shim interface
Measurement Condition
Cold Engine (≤ 35°C / 95°F)
TDC compression stroke only
Interactive Shim Sizing Calculation Engine: New Shim = Current Shim + (Measured Clearance - Target Clearance)
mm
Factory intake tolerance: 0.00 mm (Zero Lash / Hydraulic Self-Adjusting)
mm
Measured with micrometer or read laser-etched face
TDC Crankshaft Timing Index
Cam sprockets aligned with cylinder head deck; VVT phasers pinned at base timing mark.
Feeler Gauge Technique
Hydraulic lash adjusters. Zero manual feeler gauge adjustment required.

Official NHTSA Safety Recalls & Technical Bulletins

0 Open Campaigns (Clean)
U.S. Department of Transportation compliance database (Title 49 U.S.C. Chapter 301).
Verify VIN on NHTSA.gov
No Active Federal Safety Recalls Reported
The U.S. DOT National Highway Traffic Safety Administration (NHTSA) records zero open safety recall campaigns for the 2021 Harley Davidson Revolution Max 1250 / 1250T (Pan America / Sportster S) platform. Always check your individual 17-digit VIN at an authorized dealership or via NHTSA.gov for individual recall completions.
OEM Workshop Archives

Official Factory Service Bulletins & Field Updates

5 Documented Bulletins
Bulletin #M1524M1524: RECALL 0177 - 2019 - 2021 SPORTSTER - HEADLAMP BULB SHIELD
Source: Harley_M1524_Recall0177.pdf
Mandated Torques:Torque: 5.8–6 in-lbs (0.66–0.68 N·m) (Bulb Shield Screw)Torque: 35–44 in-lbs (4–5 N·m) (Bracket to Visor Screws)Torque: 10–16 ft-lbs (13.5–21.6 N·m) (Visor Bracket Screws)
Consumable Specs:Loctite 243 Medium Strength Blue Threadlocker (HD Part # 99642-97)
Genuine Part Numbers:68297-05A9150010799642-97
Fastener Stack ArchitectureExploded View: Headlamp Visor Fastener & Vibration Stack (Bulletin M1524)
3-Stage Torque Map
1. Triple Clamp Bolts (10–16 ft-lb)2. Cast Visor Eyebrow3. Visor Screws (35–44 in-lb)4. Matte Bulb Shield (91500107)5. Shield Screw: 5.8–6.0 in-lb (Loctite 243)6. H4 Quartz Bulb & SocketSelect any fastener or shield component to inspect exact torque specifications.
Component InspectorNHTSA Recall 0177 / M1524

Self-Tapping Shield Screw with Blue Loctite 243

Consumable: Loctite 243 (HD # 99642-97)
Factory Torque Specification
5.8–6.0 in-lbs (0.66–0.68 N·m) (CRITICAL LOW TORQUE)
Technical Assembly Note
MUST apply Loctite 243 Blue Threadlocker. Due to reuse of self-tapping screw into stamped bracket, STRICTLY do not exceed 6 in-lbs or threads will strip.
Vibration & Chemical Retention
Loctite 243 Medium Strength Blue Threadlocker (HD Part # 99642-97) mandatory on bulb shield screw to prevent thermal loosening.
Bulletin #M1568M1568: SAFETY RECALL 0635 - FRONT BRAKE LINE BANJO BOLT ASSEMBLY
Source: Harley_M1568_Recall0635.pdf
Mandated Torques:Torque: 19–21 ft-lbs (25.8–28.5 N·m) (Front Brake Line Banjo Bolts)
Consumable Specs:Harley-Davidson Platinum Label DOT 4 Brake Fluid
Genuine Part Numbers:2879401841751-06A41800770418007724180077341800774
Technical IllustrationExploded View: Hydraulic Brake Switch & Banjo Bolt Assembly
Official NHTSA PDF
Hover or Click Component to Inspect
19-21 FT-LB1. BOLT2. GASKET3. LINE EYE4. GASKETSWITCH BODY5. SWITCH
Component SelectedOEM # 41747-06
Cross-Drilled Banjo Bolt
Cross-drilled hydraulic passage. Torque to exact factory range. Do NOT over-tighten or bolt can shear.
Torque Specification:19–21 ft-lbs (25.5–28.5 N·m)
Select Stack Layer:
Electrical Harness Schematic40-Pin BCM Electrical Harness Pinout & Wiring Map (Bulletin M1568 / Recall 0635)
40-Way Sealed Header • Cavity F3
43214321ABCDEFGHJKLMABCDEFGHJKLMRECALL PIN F3
Click Pin F3 or center keyway to inspect technical harness specifications
Inspection TargetRecall 0635 / M1568

BCM Terminal Cavity F3 (Recall Signal Input)

Jumper Terminal Wire # 69203239
Mechanical Engagement:Terminal Click-Lock Retention
MANDATORY RECALL PIN INSERTION. Insert jumper terminal into cavity F3 of the 40-way BCM harness connector until an audible click is heard. Tug lightly to verify positive secondary terminal engagement.
Interactive Circuit Nodes:
STEP 1: HARNESS CLICK VERIFICATIONSlide terminal wire 69203239 into Cavity F3 until secondary TPA wedge clicks flush. Perform gentle pull test.
STEP 2: CHASSIS GROUND TORQUEClean left-side frame ground stud. Fasten jumper ring terminal to 45–60 in-lbs (5.1–6.8 N·m).
STEP 3: DIGITAL TECHNICIAN II SYNCFlash BCM software to 28794018 YM0+. Depress rear brake pedal to trigger auto-stop calibration countdown.
Chassis Routing ArchitectureTrike Frame Jumper Wire Routing & EHCU Ground Map (Bulletin M1568 / Recall 0635)
Figures 5 & 6 • Behind EHCU
BCM MODULEPin F3 JumperEHCU ASSEMBLY(ABS/Traction Block)GROUND STUD45–60 in-lbBRAKE SWITCH# 72025-06B#1#2#3HARLEY-DAVIDSON RECALL 0635 WIRING PATH (FIGURES 5 & 6)
Click routing channel, ground stud, cable straps, or switch to view shop notes
Chassis Routing NodeRecall 0635 / M1568

Under-Tray Sub-Harness Route (Behind EHCU)

Recall Routing Path (Figure 6)
Mechanical Anchor:Protected Chassis Channel
MANDATORY ROUTING CLEARANCE. Route jumper harness # 69203239 behind the Electro-Hydraulic Control Unit (EHCU) assembly. Keep clear of hot exhaust pipes and moving suspension linkages.
Interactive Routing Targets:
Bulletin #M1572M1572: INSTRUMENT MODULE SOFTWARE UPDATE - PAN AMERICA & SPORTSTER S
Source: Harley_M1572_SupportDocs.pdf
Bulletin #M1167Safety Recall 0118: Fuel Valve Petcock Standpipe Inversion Inspection & Replacement
Source: Harley_M1167_Recall0118.pdf
Mandated Torques:Torque: 15–20 ft-lbs (20.3–27.1 N·m) (Fuel Valve Petcock Bung Nut)
Consumable Specs:PTFE Fuel-Resistant Thread SealantViton O-Ring Fuel Gasket
Genuine Part Numbers:61338-0262169-02A61338-94D62169-95C
Hydraulic Fuel Valve SchematicExploded View: Fuel Shut-Off Valve & Standpipe (Recall 0118 / Bulletin M1167)
Torque: 15–20 ft-lbs • PTFE Sealant
TANK BUNG PORTREVERSED FLOW ORIFICE15–20 FT-LBVALVE BODY (REVISED)VACUUM CUTOFF TAP
Click standpipe, collar nut, or vacuum tap to inspect Recall 0118 specs
Inspection TargetRecall 0118 / ML-426

Reserve Standpipe Tube (Defect Analysis)

Suspect Codes: 61338-02, 62169-02A, 61338-94D
Mechanical Engagement:Internal Hydraulic Passage
RECALL 0118 DEFECT LOCUS. Supplier inverted the valve rotor passages. Setting lever to ON drew fuel through the short bottom reserve hole, while RESERVE drew from the tall standpipe, leaving rider with zero reserve fuel.
Interactive Assembly Nodes:
Bulletin #M1720M1720 (REV A): PAN AMERICA ECM & BCM COLD START & QUICKSHIFTER UPDATE
Source: NHTSA_MC_11034748_M1720.pdf
Genuine Part Numbers:Special Tool: DIGITAL TECHNICIAN II (HD-48650)

Explore Other Subsystems for this 2021 Harley Davidson Revolution Max 1250 / 1250T (Pan America / Sportster S)

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Subsystem Guide/torques

Fastener Torques

Engine drain plug, axle spindles, caliper mounts, triple clamp pinch bolts & thread lubrication derating guide.

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Subsystem Guide/fluids

Fluids & Capacities

Oil: 4.50 L (4.75 US qt) • Coolant: N/A • Brake: DOT 4 Platinum Glycol Ether High-Temp

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Subsystem Guide/fuses-relays

Fuses & Relays

Main: 50A Main Fuse • Location: N/A

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Subsystem Guide/compression

Compression & Leakdown

Ratio: 13.0:1 (Pan America) / 12.0:1 (Sportster S) • Std: 190-225 PSI • Limit: 155 PSI

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Subsystem Guide/fuel-delivery

Fuel Delivery & TB Sync

Idle: N/A • Rail Pressure: N/A • Vacuum: N/A

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Subsystem Guide/electrical

Charging & Battery

Battery: YTX14-BS / YTX20HL-BS • CCA: 310 • Regulated: 14.2 - 14.8 V DC at 3,000 RPM

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Subsystem Guide/tires

Tires & Gearing

Front: 120/70R19 (Pan America) / 160/70R17 (Sportster S) • Rear: 170/60R17 (Pan America) / 180/70R16 (Sportster S)

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Subsystem Guide/suspension

Suspension & Sag

Front Travel: 190 mm • Rear Travel: 190 mm

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Subsystem Guide/maintenance

Maintenance Schedule

Oil: Every 5,000 mi (8,000 km) mi • Valves: N/A • Plugs: Every 30,000 mi (48,000 km) Iridium mi

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