Dedicated Subsystem WorkbenchPlatform Gen: 2021–2026

2024 Harley Davidson Revolution Max 1250 / 1250T (Pan America / Sportster S) Tire Sizes, Cold Pressures & Gearing Ratios

OEM tire sizes, front cold PSI (), rear cold PSI (), sprocket teeth count, final drive ratio, and chain pitch for 2024 Harley Davidson Revolution Max 1250 / 1250T (Pan America / Sportster S).

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 Items3 Verified Workshop Consumables Available for this Job

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Tire Engineering & Multi-Scenario Pressure Matrix

ETRTO Validated

Inflation targets calibrated across operating modes, verified rim width ranges, and certified alternate sizes.

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Multi-Scenario Inflation Pressures

Solo Street / CommutingCold Baseline

Front: 36 PSI

Rear: 42 PSI

Two-Up Passenger & LuggageMax Load

Front: 38 PSI

Rear: 44 PSI

Off-Highway / Terrain Pressure

Maintain OEM cold baseline for street transfers; adjust -2 to -4 PSI for loose terrain.

Rim Geometry & ETRTO Envelopes

Front Wheel

OEM Rim Width:3.50"

Permissible Envelope:3.50" - 3.75"

Rear Wheel

OEM Rim Width:5.00"

Permissible Envelope:5.00" - 5.50"

Operating outside ETRTO envelope width alters crown radius, accelerates shoulder wear, and impacts lean stability.

Factory Dimensions & Verified Alternates

Factory Standard Sizes

Front:120/70R19 (Pan America) / 160/70R17 (Sportster S)

Rear:170/60R17 (Pan America) / 180/70R16 (Sportster S)

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Verified Alternate Fitments

Michelin Scorcher Adventure (Pan America)

Dunlop GT503 (Sportster S)

Alternate profiles verified for swingarm, chain guard, and fender clearances.

Final Drive Gearing & Speed/RPM Calculator

Chain Drive (Pan America) / Belt Drive (Sportster S)

Factory reduction ratios, interactive sprocket gearing simulator, 6th gear cruising RPM matrix, and swingarm chain adjustment tolerances.

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Drive Ratio & Torque Impact

Calculated Final RatioStock: 2.526

2.526 : 1+0.01%

Drivetrain Torque Delta

+0.0% Rear Wheel Torque Increase

Quicker throttle roll-on response and aggressive low-to-mid range launch. Reduces top speed in each gear proportionally.

Countershaft Speedo Variance:-0.0%

At 70.0 mph indicated speed, true vehicle ground speed is 70.0 mph. Speedo calibrator module recommended.

Cruising Engine RPM in 6th Gear

60 MPH

Stock: 2,797 RPM

2,797 RPM

70 MPH

Stock: 3,263 RPM

3,263 RPM

80 MPH

Stock: 3,729 RPM

3,730 RPM

+1 RPM

Calculated using factory 6th gear ratio (0.84), primary reduction (1.636), and 170/60R17 (Pan America) / 180/70R16 (Sportster S) rolling circumference.

Cardan Bevel Gear Maintenance

Recommended Belt: DID 525 ZVM-X Super Street X-Ring Chain

Shop Bevel Gear Oil Find Direct-Fit Gearing Sets

Factory Chassis Geometry

Chassis Alignment, Drive Tension & Rear Axle Calibration

Precision workshop alignment tools, dynamic drive tension tolerances, and axle spindle calibration for the 2024 Harley Davidson Revolution Max 1250 / 1250T (Pan America / Sportster S).

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/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/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/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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