Harley Davidson 2013 Sportster Models. Service Manual — page 18
sm06691
Figure 2-148. Rod Guide Nut Socket
sm06696
Figure 2-149. Piston Rod Assembly with Rod Case Guide
Drain the Fork Oil
1.
See
. Drain the oil into a pan. Remove:
a.
The upper spring collar
b.
The spring
c.
The lower spring collar
2.
Pump the inner tube 10 or more times to empty the oil
from the fork.
NOTE
Dispose of fork oil in accordance with local regulations.
sm06697
Figure 2-150. Remove the Upper Spring Collar and the
Spring
Complete Disassembly
1.
See
. Remove the stopper ring (18) from the
groove inside the outer tube (13).
2.
Slide the inner tube (20) out of the outer tube.
3.
From the inner tube remove:
a.
Slide bushing (14)
b.
Guide bushing (15)
c.
Seal spacer (16)
d.
Oil seal (17)
e.
The stopper ring
f.
The dust seal (19)
2-104 2013 Sportster Service: Chassis
1
3
19
16
2
4
18
11
7
15
13
10
6
14
8
12
20
9
17
5
sm06707
11.
1.
Spring
Fork tube cap
2.
12.
O-ring
Lower spring collar
13.
3.
Outer tube
Slider ring
4.
14.
O-ring
Slider bushing
15.
5.
Guide bushing
Rod guide case
6.
16.
Hex nut
Seal spacer
17.
7.
Oil seal
Preload spring
8.
18.
Rod piston assembly
Stopper ring
19.
9.
Dust seal
Piston ring
10.
20.
Upper spring collar
Inner tube
Figure 2-151. Fork Assembly: XR 1200X
CLEANING AND INSPECTION
1.
Thoroughly clean components.
2.
Replace all oil seals and O-rings.
3.
Inspect components. Replace as necessary.
a.
Fork tube bushing and slider guide bushing for wear.
b.
Dust cover (where it rubs on fork tube) for wear.
c.
Springs for damaged coils.
d.
Fork tube or slider for bends or wear.
2013 Sportster Service: Chassis 2-105
ASSEMBLY
TOOL NAME
PART NUMBER
FORK SEAL DRIVER AND DUST
BOOT INSTALLER
B-42571
OIL LEVEL GAUGE
B-59000B
FORK HOLDING TOOL
HD-41177
ROD CASE GUIDE SOCKET
HD-50083
FORK CAP WRENCH
HD-50084
TORQUE VALUE
FASTENER
26-30 Nm
19-22 ft-lbs
Fork piston rod hex nut: XR
1200X
90 Nm
66 ft-lbs
Rod guide case to inner tube:
XR 1200X
29-39 Nm
21-29 ft-lbs
Fork cap to outer tube: XR
1200X
Piston Rod Service
1.
Separate the hex nut from the fork cap and remove the
fork cap and hex nut from the piston rod assembly.
NOTES
•
The piston rod assembly should not be disassembled any
further than is described.
•
Do not use TYPE "E" HYDRAULIC FORK OIL to lubricate
the components for assembly. Use BIG PISTON FORK
OIL.
2.
See
. Replace the O-ring on the fork cap.
3.
See
. Replace the rod guide case O-ring (1)
and the slider ring (2).
4.
Replace the rebound spring.
5.
See
. Replace the fork piston ring.
6.
Install the hex nut and the fork cap on the piston rod
assembly.
7.
Tighten to 19-22 ft-lbs (26-30 Nm).
sm06701
Figure 2-152. Fork Cap and O-Ring
2
1
sm06703
1. Rubber O-ring
2. Slider ring
Figure 2-153. Rod Guide Case and O-Rings
sm06702
Figure 2-154. Fork Rod Piston and Ring
Initial Assembly
1.
See
. Install on the inner fork tube:
a.
Dust seal (1)
b.
Oil seal stopper ring (2)
c.
Seal with the stamp side down (3)
d.
Seal spacer with the chamfer up (4)
e.
Guide bushing (6)
f.
Slide bushing (5)
NOTE
Do not use TYPE "E" HYDRAULIC FORK OIL to lubricate the
components for assembly. Use BIG PISTON FORK OIL to
lubricate the components for assembly.
2.
Spread fork oil or sealing grease inside the lip of the oil
seal.
3.
Slide the inner tube into the outer tube.
2-106 2013 Sportster Service: Chassis
4.
See
. Seat the oil seal with the FORK SEAL
DRIVER AND DUST BOOT INSTALLER (Part No. B-
42571).
5.
Snap the stopper ring into the groove in the outer tube.
6.
Seat the dust seal with the seal driver.
4
1
6
3
5
2
sm06698
1. Dust seal
2. Stopper ring
3. Oil seal
4. Spacer ring
5. Slide bushing
6. Guide bushing
Figure 2-155. Inner Tube Components
sm06699
Figure 2-156. Seating the Oil Seal
Fill with Fork Oil
1.
Mount the fork assembly in the FORK HOLDING TOOL
(Part No. HD-41177) and fully compress the inner tube.
NOTE
Measure the fork spring. Replace as necessary. Refer to
2.
Install:
a.
Lower spring collar
b.
Fork spring
c.
Upper spring collar
NOTE
Do not use TYPE "E" HYDRAULIC FORK OIL in the XR 1200X
forks.
3.
Fill fork with BIG PISTON FORK OIL until the oil reaches
the side hole in the inner tube.
4.
Pump the outer tube 8-10 times to expel the air from the
assembly.
NOTE
Do not damage the slide ring on the rod guide case.
5.
Install the piston assembly:
a.
Guide the piston rod into the inner tube.
b.
Hand tighten the rod guide case to the inner tube.
c.
Gently pull up on the outer tube to fit the slider ring
to the outer tube.
6.
Using the ROD CASE GUIDE SOCKET (Part No. HD-
50083), tighten to 66 ft-lbs (90 Nm).
7.
Fill fork with addition BIG PISTON FORK OIL until the oil
spills over the rod guide case.
8.
Pump the piston assembly/outer tube several times to
expel any additional air.
2013 Sportster Service: Chassis 2-107
9.
See
. Use the OIL LEVEL GAUGE (Part
No. B-59000B) to set the level of the oil in the outer fork
tube to specification. Refer to
Table 2-22. Minimum Spring Service Length
mm
in
MODEL
346.6
13.65
XR 1200X
Table 2-23. Fork Oil Volume
cm
3
oz
MODEL
580
19.6
XR 1200X
Table 2-24. Fork Oil Level
mm
in
MODEL
45
1.77
XR 1200X
sm06700
Figure 2-157. Drawing Off Excess Fork Oil
Complete Assembly
1.
Use the FORK CAP WRENCH (Part No. HD-50084) to
install the fork cap and tighten to 21-29 ft-lbs (29-39 Nm).
2.
Adjust the preload to identical settings on both forks.
INSTALLATION
TOOL NAME
PART NUMBER
TRIPLE TREE WEDGE TOOL
HD-48287
TORQUE VALUE
FASTENER
40.7-47.5 Nm
30-35 ft-lbs
Fork, front, bracket pinch
screw
NOTES
•
Fork tube installation height must match the opposite side
exactly for proper vehicle operation, reliability and perform-
ance.
•
When installing fork leg in fork brackets, do not twist fork
leg to avoid damage to cosmetic finishes.
1.
Identify left and right side fork assemblies.
2.
Insert fork assembly from the lower fork bracket upward
through the upper fork bracket.
3.
Remove TRIPLE TREE WEDGE TOOL (Part No. HD-
48287) used during removal process.
4.
See
. Measure fork tube installation height.
Adjust fork tubes to specification. Refer to
.
sm05356
Figure 2-158. Fork Installation Height Measurement
Table 2-25. Fork Installation Height Specifications
mm
in
MODEL
9.86-11.88
0.388-0.468
XR 1200X
5.
Tighten pinch bolts to 30-35 ft-lbs (40.7-47.5 Nm).
6.
Install front fender and bracket. See
.
7.
Install front brake caliper hydraulic lines and install front
brake calipers. See
8.
Install front wheel and align the wheel to the forks. See
.
2-108 2013 Sportster Service: Chassis
2.21
FORK STEM AND BRACKET ASSEMBLY
REMOVAL AND DISASSEMBLY
1.
Cover the fuel tank.
2.
Remove the fork assemblies. See
or
3.
See
. Loosen fork stem pinch screw (7).
Remove fork stem bolt (9) and washer (8).
4.
Lift handlebar assembly from steering head with fork upper
bracket (6) attached. Carefully position assembly out of
the way. Exercise caution to avoid damaging control
cables, wiring harnesses, clutch cable or brake lines.
NOTE
Only disconnect handlebar connections if removing as an
assembly.
5.
Remove upper seal (5) and upper bearing cone (3). Slide
fork stem and lower bracket (1) from frame.
1
11
2
6
3
4
12
4
3
5
7
9
8
10
sm06711
1. Fork stem and lower bracket
2. Seal, lower
3. Bearing cone (2)
4. Bearing cup (2)
5. Seal, upper
6. Fork upper bracket
7. Fork stem pinch screw
8. Washer
9. Fork stem bolt
10. Pinch screw, upper (2)
11. Pinch screw, lower (2)
12. Steering head (part of frame)
Figure 2-159. Fork Stem and Bracket Assembly: Typical
2013 Sportster Service: Chassis 2-109
CLEANING, INSPECTION AND REPAIR
TOOL NAME
PART NUMBER
UNIVERSAL DRIVER HANDLE
HD-33416
STEERING HEAD BEARING RACE
REMOVAL TOOL
HD-39301-A
1.
See
. Clean the seals (2, 5), bearing cones
(3), fork stem and lower bracket (1) and steering head (12)
with solvent.
2.
Inspect fork stem and lower bracket (1). Replace as
necessary.
NOTE
Replace bearings and bearing cups as a set.
3.
Inspect bearings. Replace as necessary.
a.
Pitting or scoring
b.
Wear
c.
Scoring
4.
Turn the bearings in the races to check for roughness.
Replace as necessary.
Replace both bearing assemblies even if one assembly
appeares to be good. Mismatched bearings can lead to
excessive wear and premature replacement. (00532b)
5.
Replace bearings and bearing cups as follows:
a.
The lower bearing cone is a slip fit on the fork stem.
Remove lower bearing cone by sliding it up and off
fork stem. If necessary, gently pry bearing cone off
fork stem with a pair of flat blade screw drivers.
Remove lower seal (2).
b.
Drive bearing cups from steering head using
STEERING HEAD BEARING RACE REMOVAL TOOL
(Part No. HD-39301-A) and UNIVERSAL DRIVER
HANDLE (Part No. HD-33416).
If bearing cups are
removed, the bearings cannot be reused. They
must be replaced.
ASSEMBLY AND INSTALLATION
TOOL NAME
PART NUMBER
STEERING HEAD BEARING RACE
INSTALLATION TOOL
HD-39302
TORQUE VALUE
FASTENER
31.2-36.6 Nm
23-27 ft-lbs
Fork, front, stem bolt, 1st
torque
8.1-10.9 Nm
72-96
in-lbs
Fork, front, stem bolt, final
torque
40.7-47.5 Nm
30-35 ft-lbs
Fork stem pinch bolt
40.7-47.5 Nm
30-35 ft-lbs
Fork stem pinch bolt
1.
See
. If bearing cups (4) were removed, obtain
new
bearings and bearing cups. Install
new
bearing cups
into frame steering head using STEERING HEAD
BEARING RACE INSTALLATION TOOL (Part No. HD-
39302).
Properly seat bearing cups in steering head bore. Improper
seating can loosen fork stem bearings adversely affecting
stability and handling, which could result in death or ser-
ious injury. (00302a)
2.
Liberally coat the bearing cones (3) with SPECIAL PUR-
POSE GREASE. Work the grease thoroughly into the
bearing rollers.
3.
Place lower bearing seal (2) over fork stem. Install lower
bearing cone (3) onto fork stem and bracket (1).
4.
Insert fork stem and bracket (1) through the steering head.
Install bearing cone (3) and seal (5) onto the stem.
5.
Install the upper bracket (6) including the handlebar
assembly and loosely install fork stem bolt (9) with washer
(8).
6.
Install fork slider and tube assemblies. See
or
Leave both lower fork bracket pinch screws (11) loose.
7.
Tighten fork stem bolt (9) to 23-27 ft-lbs (31.2-36.6 Nm).
Loosen fork stem bolt, then retighten to 72-96
in-lbs
(8.1-
10.9 Nm).
8.
Tighten lower fork bracket pinch bolt to 30-35 ft-lbs (40.7-
47.5 Nm).
9.
Tighten fork stem pinch screw (7) to 30-35 ft-lbs (40.7-
47.5 Nm).
10. Adjust
steering
head
bearing
fall-away.
See
1.19 STEERING HEAD BEARINGS, Fall-Away
2-110 2013 Sportster Service: Chassis
2.22
BELT GUARD AND DEBRIS DEFLECTOR
BELT GUARD: XL MODELS
TORQUE VALUE
FASTENER
13.6-20.4 Nm
120-180
in-lbs
Belt guard screw: XL Models
61-68 Nm
45-50 ft-lbs
Shock absorber mounting bolt
Removal
1.
See
. Remove right side lower shock absorber
mount locknut (1).
2.
Pull shock absorber mounting bolt (2) out slightly until it
clears mounting hole in belt guard (4).
3.
Remove screw (5), washer (6) and nut (7) securing front
of belt guard to rear fork (10).
Installation
1.
See
. Slide belt guard (4) into place. Tab on
front of belt guard mounts outboard of mounting bracket
on rear fork.
2.
Secure front of belt guard to rear fork (10) with screw (5),
washer (6) and nut (7). Tighten to 120-180
in-lbs
(13.6-
20.4 Nm).
3.
Push lower shock absorber bolt (2) through rear belt guard
mounting hole. Thread locknut (1) on screw. Tighten to
45-50 ft-lbs (61-68 Nm).
DEBRIS DEFLECTOR: XL MODELS
TORQUE VALUE
FASTENER
4.1-6.8 Nm
36-60
in-lbs
Debris deflector screw: XL
Models
Removal
1.
See
. Loosen, but do not remove, three
screws with captive washers (9) securing debris deflector
(8) to underside of rear fork (10).
2.
Slide debris deflector forward until keyway slots in deflector
clear screw heads.
Installation
1.
See
. Position debris deflector (8) in place on
underside of rear fork (10).
2.
Fit large end of keyway slots in deflector over screw heads
and captive washers (9). Slide deflector rearward to lock
screws in slots.
3.
Tighten to 36-60
in-lbs
(4.1-6.8 Nm).
4
3
2
8
9
10
7
1
5
6
sm01358a
1. Locknut
2. Mounting bolt
3. Washer
4. Belt guard
5. Screw
6. Washer
7. Nut
8. Debris deflector
9. Screw with captive washer (3)
10. Rear fork
Figure 2-160. Belt Guard/Debris Deflector: XL Models
BELT GUARD: XR 1200X
TORQUE VALUE
FASTENER
8.1-10.8 Nm
72-96
in-lbs
Belt guard screw: XR 1200X
Removal
See
. Remove two screws with captive washers
(2) securing belt guard to top of rear fork (5).
Installation
1.
See
. Slide belt guard (1) into place on top
of rear fork (5).
2.
Install two screws with captive washers (2).
3.
Tighten to 72-96
in-lbs
(8.1-10.8 Nm).
2013 Sportster Service: Chassis 2-111
DEBRIS DEFLECTOR: XR 1200X
TORQUE VALUE
FASTENER
8.1-10.8 Nm
72-96
in-lbs
Debris deflector screw: XR
1200X
Removal
NOTE
Front screw is located inboard of debris deflector.
See
. Remove three screws with captive washers
(4) securing debris deflector (3) to underside of rear fork (5).
Installation
1.
See
. Position debris deflector (3) in place on
underside of rear fork (5).
2.
Install three screws (4).
3.
Tighten to 72-96
in-lbs
(8.1-10.8 Nm).
1
2
3
5
4
sm04892
1. Belt guard
2. Screw with captive washer (2)
3. Debris deflector
4. Screw with captive washer (3) (front screw
inboard of debris deflector)
5. Rear fork
Figure 2-161. Belt Guard/Debris Deflector: XR 1200X
2-112 2013 Sportster Service: Chassis
2.23
REAR FORK
REMOVAL
NOTE
Label hardware for location and orientation upon removal.
1.
Position motorcycle on a suitable lift.
2.
XL models:
Remove rear exhaust pipe and muffler. See
4.13 EXHAUST SYSTEM: XL MODELS
.
3.
XR 1200X:
Remove exhaust system. See
4.
Remove rear wheel. See
.
5.
Remove rear brake caliper assembly from rear fork. See
2.14 REAR BRAKE CALIPER: XL MODELS
or
6.
Remove screw(s) securing brake line clamp(s) to rear fork.
7.
XR 1200X:
Remove fasteners securing brake line to left
side of rear fork.
8.
Remove both shock absorber screws, washers and nuts
from rear fork. See
.
9.
Remove rear belt guard and debris deflector. See
2.22 BELT GUARD AND DEBRIS DEFLECTOR
.
10.
XL Models:
Remove rear brake reservoir cover by
grasping cover and gently pulling straight out from reser-
voir. Remove reservoir mounting screw and pull reservoir
back out of the way. See
11.
XL Models:
Loosen, but do not remove, top mounting
screw from left passenger footrest bracket. Remove bottom
mounting screw. Move brake hoses and clamp forward
slightly to gain access to left rear fork/engine mount bolt.
12.
XR 1200X:
Remove left and right rider footrests. See
2.42 RIDER FOOT CONTROLS: XR 1200X
.
13. See
. Support rear fork (3). Remove rear
fork/engine mount bolts (1) and pull fork assembly from
frame.
5
4
3
6
1
2
sm01818
1. Bolt (2)
2. Bearing (2)
3. Rear fork
4. Pivot shaft
5. Frame
6. Retaining ring
Figure 2-162. Rear Fork Assembly
DISASSEMBLY
TOOL NAME
PART NUMBER
BEARING REMOVER/INSTALLER
TOOL
HD-46281
NOTE
See
. Remove pivot bearings (2) only if replace-
ment is required.
1.
S e e
.
U s i n g
B E A R I N G
REMOVER/INSTALLER TOOL (Part No. HD-46281) (4,
5, 6), carefully press bearing assemblies from fork bearing
bosses (2):
a.
Place receiver cup (6) on press bed, with recessed
end of cup facing up.
b.
Place rear fork pivot bearing boss (2) over cup as
shown in the photo.
c.
Slide pilot (5) through bearing and into receiver cup.
d.
Insert handle (4) through other rear fork pivot bearing
boss and bearing, down into pilot.
e.
Engage press ram on end of handle and press
bearing out.
2.
Turn rear fork over. Press out the opposite pivot bearing.
2013 Sportster Service: Chassis 2-113
1
3
4
5
6
2
sm01465
1. Rear fork
2. Pivot bearing boss
3. Press
4. Handle
5. Pilot
6. Receiver cup
Figure 2-163. Removing Rear Fork Pivot Bearings
CLEANING AND INSPECTION
1.
Clean all components in solvent.
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)
2.
Blow dry with low pressure compressed air.
3.
Carefully inspect bearings for wear and/or corrosion.
Replace as necessary.
4.
See
. Make sure pivot bearing retaining ring
(6) is not bent or damaged. If it is, replace it with a
new
retaining ring.
5.
Make sure retaining ring is fully seated in the groove in
each bearing (2).
6.
Check that rear fork (3) is not bent, twisted or cracked.
Replace as necessary.
ASSEMBLY
TOOL NAME
PART NUMBER
BEARING REMOVER/INSTALLER
TOOL
HD-46281
1.
See
. If necessary, press
new
bearings (2)
into
position
in
rear
fork,
using
BEARING
REMOVER/INSTALLER TOOL (Part No. HD-46281):
a.
See
. Place receiver cup (7) on press
bed, with recessed end of cup facing up.
b.
Place rear fork pivot bearing boss (2) over cup as
shown in the photo.
c.
Place
new
pivot bearing (6) over pivot bearing boss,
with retaining ring side of bearing up.
d.
Slide pilot (5) through
new
pivot bearing, through pivot
bearing boss, and into receiver cup.
e.
Insert handle (4) down into pilot.
f.
Engage press ram on end of handle and press
bearing down until retaining ring bottoms out in rear
fork pivot bearing boss.
2.
Turn rear fork over. Press the other pivot bearing into rear
fork pivot bearing boss.
INSTALLATION
TORQUE VALUE
FASTENER
81.4-95.0 Nm
60-70 ft-lbs
Fork, rear, pivot/engine mount
bolt
61-68 Nm
45-50 ft-lbs
Footrest mount fastener
2.3-2.8 Nm
20-25
in-lbs
Brake master cylinder reser-
voir, rear, mounting screw
1.
Slide rear fork assembly into position on motorcycle.
2.
See
. Holding rear fork assembly in position,
install rear fork/engine mount bolts (1). Tighten to 60-70
ft-lbs (81.4-95.0 Nm).
3.
XL Models:
Position rear brake hose clamp and left pas-
senger footrest bracket in place. Install lower mounting
screw. Tighten both mounting screws to 45-50 ft-lbs (61-
68 Nm).
4.
XL Models:
Install rear brake reservoir using screw with
captive washer. Tighten to 20-25
in-lbs
(2.3-2.8 Nm).
Place reservoir cover over reservoir and gently press cover
into place. See
2.13 REAR BRAKE MASTER CYLINDER
5.
XR 1200X:
Install left and right rider footrests. See
2.42 RIDER FOOT CONTROLS: XR 1200X
6.
Install belt guard and debris deflector. See
7.
Install shock absorbers onto rear fork. See
2-114 2013 Sportster Service: Chassis
8.
Install rear brake caliper assembly. See
or
.
9.
XR 1200X:
Secure rear brake line to left side of fork. See
10. Install rear wheel and adjust rear belt. See
.
11.
XL Models:
Install rear exhaust pipe and muffler. See
4.13 EXHAUST SYSTEM: XL MODELS
.
12.
XR 1200X:
Install exhaust system. See
2
1
3
4
5
6
7
4
5
6
7
sm01466
1. Rear fork
2. Pivot bearing boss
3. Press
4. Handle
5. Pilot
6. Bearing
7. Receiver cup
Figure 2-164. Installing Rear Fork Pivot Bearings
2013 Sportster Service: Chassis 2-115
2.24
SHOCK ABSORBERS
REMOVAL
NOTES
•
If a lift is not available, remove and install one shock
absorber at at time.
•
If necessary to remove saree guards, see
GUARD: INDIA MODELS, Saree Guard: XL 883R, XL
1200C/C ANV (India)
.
1.
Note the shock absorber settings.
a.
All Models:
Preload.
b.
XR 1200X:
Rebound and compression.
2.
See
. Remove fastener (1), washer (2) and
locknut (3) from bottom end of the shock absorber (4 or
5).
3.
Remove the fastener (6) and washer (7 or 2) from top end
of shock absorber.
4.
XL Models:
Remove the stud cover (8).
5.
Remove the shock absorber.
CLEANING AND INSPECTION
NOTE
Replace shock absorbers as set if either unit is damaged.
1.
Clean and inspect all parts for wear and damage.
2.
Check rubber bushings for wear, cracking and stiffness.
3.
Examine shock absorber for signs of leakage.
INSTALLATION
TORQUE VALUE
FASTENER
61-68 Nm
45-50 ft-lbs
Shock absorber mounting bolt
61-68 Nm
45-50 ft-lbs
Shock absorber mounting bolt
1.
See
. Assemble the upper fastener stack.
a.
XL Models:
Assemble the upper fastener (6), the
washer (7) and the stud cover (8).
b.
XR 1200X:
Assemble the upper fastener (6) and the
washer (2).
2.
Install shock absorber mounting stack through the shock
absorber (4 or 5).
3.
Position bottom end of shock absorber against outboard
side of rear fork mount. Insert mounting bolt (1) and
washer (2) through the damper bushing (9) and the rear
fork mount.
4.
Thread on the locknut (3).
5.
Remove the upper mounting bolt and apply 2-3 drops of
LOCTITE 243 MEDIUM STRENGTH THREADLOCKER
AND SEALANT (blue) to the threads.
6.
Install the mounting bolt into the frame boss. Tighten to
45-50 ft-lbs (61-68 Nm).
7.
Tighten the lower shock absorber locknut to 45-50 ft-lbs
(61-68 Nm).
8.
Adjust the shock absorber to the original settings.
a.
All Models:
Preload.
b.
XR 1200X:
Rebound and Compression.
5
9
9
3
2
1
4
8
6
7
2
1
9
6
3
9
2
sm01819C
1. Mounting bolt
2. Washer
3. Locknut
4. Shock absorber: XL models
5. Shock absorber: XR 1200X
6. Mounting bolt
7. Washer
8. Stud cover: XL models
9. Damper bushing
Figure 2-165. Shock Absorbers: All Models
2-116 2013 Sportster Service: Chassis
SHOCK DISPOSAL: SCHRADER VALVE
MODELS
1.
Remove the shock.
2.
See
. Locate the valve.
NOTE
Cap may require pliers to remove.
3.
Remove the valve cap.
Discharging pressurized oil and gas can pierce skin and
cause flying debris, which could cause serious injury.
Wear safety glasses and gloves. (00601b)
4.
Press the valve stem with a flat blade screwdriver to
release the gas.
5.
Dispose of the shock.
sm06708
Figure 2-166. Schrader Valve Location: XR 1200X
2013 Sportster Service: Chassis 2-117
2.25
STABILIZER LINKS
GENERAL
The stabilizer link system allows the engine to move on its
rubber engine mounts while maintaining engine-to-frame
alignment. The stabilizer links provide a fixed alignment, and
no adjustment is necessary or possible.
The spherical ball end of the stabilizer may rotate loosely, but
should not have lateral movement. Replace the link if lateral
movement exists.
UPPER FRONT STABILIZER LINK
TORQUE VALUE
FASTENER
74.6-88.2 Nm
55-65 ft-lbs
Stabilizer link, upper front,
engine bracket mounting
screw
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link, upper front,
frame bracket mounting screw
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screw
Removal
1.
See
. Remove screws (4) and stabilizer link
(2).
NOTE
Models with a side-mounted horn do not include a horn bracket
(9).
2.
Remove screws (5), washers (8), horn bracket (9) and
upper frame bracket (3) from frame.
3.
Remove screws (6), lockwashers (7) and engine bracket
(1) from front cylinder head.
Installation
1.
See
. Install screws (6), lockwashers (7) and
engine bracket (1) to front cylinder head. Tighten to 55-65
ft-lbs (74.6-88.2 Nm).
NOTE
Models with a side-mounted horn do not include a horn bracket
(9).
2.
Install upper frame bracket (3), horn bracket (9), screws
(5) and washers (8). Tighten to 25-35 ft-lbs (33.9-47.5
Nm).
3.
Install stabilizer link (2) with screws (4). Tighten to 25-35
ft-lbs (33.9-47.5 Nm).
4
7
9
5
8
6
1
2
3
4
sm03439b
1. Engine bracket
2. Upper stabilizer link
3. Upper frame bracket
4. Screw
5. Screw (2)
6. Screw (2)
7. Lockwasher (2)
8. Washer (2)
9. Horn bracket (front mount models)
Figure 2-167. Upper Front Stabilizer Link Assembly
LOWER FRONT STABILIZER LINK
TORQUE VALUE
FASTENER
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link, lower front,
frame bracket mounting screw
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screw
Removal
1.
Position motorcycle upright on suitable lift.
2.
See
. Remove screws (3) and stabilizer link
(1).
3.
Remove screws (4), washers (5) and lower frame bracket
(2) from frame.
Installation
1.
See
. Install screws (4), washers (5) and lower
frame bracket (2) to frame. Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).
2.
Install stabilizer link (1). Secure with screws (3). Tighten
to 25-35 ft-lbs (33.9-47.5 Nm).
2-118 2013 Sportster Service: Chassis
4
5
2
1
3
sm03440a
1. Lower stabilizer link
2. Lower frame bracket
3. Screw (2)
4. Screw (2)
5. Washer (2)
Figure 2-168. Lower Front Stabilizer Link Assembly
(typical)
REAR STABILIZER LINK
TORQUE VALUE
FASTENER
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screw
Removal
1.
Motorcycles Equipped with EVAP Controls:
Remove
EVAP canister and mounting bracket. See
ATIVE EMISSIONS CONTROL, Charcoal Canister
.
2.
See
. Remove short screw (3), long screw
(4), ground strap (2), stabilizer link (1) and spacer (5).
Installation
1.
See
. Install short screw (3) through ground
strap (2) and stabilizer link (1). Thread screw into frame
on right side of motorcycle. Do not tighten at this time.
2.
Install long screw (4) through ground strap, stabilizer link
and spacer (5) into engine case.
NOTES
•
XL Models: Orient the ground strap so it does not come
into contact with the EVAP canister mounting hardware.
•
XR 1200X: Check that the ground strap does not contact
the rear stop switch harness before tightening stabilizer
link screws.
3.
Tighten both screws to 25-35 ft-lbs (33.9-47.5 Nm).
4.
Motorcycles Equipped with EVAP Controls:
Install
EVAP canister and mounting bracket. See
ATIVE EMISSIONS CONTROL, Charcoal Canister
5
4
3
2
1
sm03428b
1. Stabilizer link
2. Grounding strap
3. Screw
4. Screw
5. Spacer
Figure 2-169. Rear Stabilizer Link Assembly (typical)
2013 Sportster Service: Chassis 2-119
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