Dedicated Subsystem WorkbenchPlatform Gen: 2021–2026

2024 Harley Davidson Revolution Max 1250 / 1250T (Pan America / Sportster S) Cylinder Compression & Leakdown Diagnostic Engine

Factory compression specs for 2024 Harley Davidson Revolution Max 1250 / 1250T (Pan America / Sportster S): standard pressure 190 - 225 PSI (1310 - 1551 kPa), service limit 155 PSI, dry vs wet test diagnostics and acoustic leak stethoscope.

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: 2024)
6 Production Years (2021–2026)

2021 2022 2023 2024 2025 2026

Suggested Items4 Verified Workshop Consumables Available for this Job

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Cylinder Compression & Leakdown Diagnostic Engine

Multi-Cylinder Dry vs. Wet Test Bench, Differential Pressure Regulator & Acoustic Stethoscope Locator

Ratio: 13.0:1 (Pan America) / 12.0:1 (Sportster S)Std: 190-225 PSILimit: 155 PSIWhip Adapter: 10 mm × 1.0

Electronic / Mechanical ACR Camshaft Decompression

Cams feature centrifugal automatic decompression mechanisms on exhaust cams. Full compression readings are achieved once starter reaches 300+ RPM.

Diagnostic Presets:

Cyl #1 (Front)IN-SPEC

213PSI(1469 kPa)

Cyl #2 (Rear)IN-SPEC

211PSI(1455 kPa)

Cross-Cylinder Variance: Δ 2 PSI (OEM Limit: ≤ 15 PSI)

VARIANCE IN-SPEC

All cylinders demonstrate strong, balanced mechanical sealing. Piston ring packs, cylinder cross-hatch, and valve seats are within factory specification.

Official Workshop Manual Compression Test Protocol

Step 0 of 5 Completed

Step 1: Engine Operating Temperature

Run engine until coolant reaches 60°C - 80°C (140°F - 176°F). Cylinder expansion brings rings and pistons to true operating clearances.

Step 2: Spark Plug Removal & Port Clean

Blow compressed air around spark plug wells to eject grit, then remove all spark plugs. Thread in 10 mm × 1.0 whip adapter hand-tight with fresh O-ring.

Step 3: Wide-Open Throttle (WOT) Lock

Hold throttle grip fully wide open (or lock throttle bodies open) to eliminate intake butterfly vacuum restriction and ensure 100% volumetric cylinder filling.

Step 4: Battery Tender Voltage Stabilization

Connect a 12V shop battery tender or booster. Starter must sustain uninterrupted cranking speed (320 RPM) to build maximum dynamic stroke pressure.

Step 5: Crank 4-6 Compression Strokes

Engage starter until gauge needle ceases rising (typically 4 to 6 strokes). Record maximum peak pressure and compare against the OEM limits above.

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 2024 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

Select 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

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

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

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

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 2024 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/valves

Valve Clearances

Intake: N/A mm • Exhaust: N/A mm

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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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