Harley Davidson 2013 Sportster Models. Service Manual — page 8

2.

Install primary cover, left footrest assembly and gear shift
lever. See

5.3 PRIMARY COVER

.

3.

Connect battery. See

1.22 BATTERY MAINTENANCE

.

4.

Test charging system. See electrical diagnostic manual.

2

3

1

sm01164

1. Rotor
2. Sprocket
3. Pipe section

Figure 6-101. Pressing Rotor onto Sprocket (XL Models

Only)

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6-66 2013 Sportster Service: Electrical

6.25

VEHICLE SPEED SENSOR (VSS)

GENERAL

The VSS is powered and monitored by the ECM. The ECM
processes the vehicle speed signal and transmits this signal
to the TSM/TSSM and speedometer through serial data.

NOTE

This part cannot be repaired. Replace upon failure.

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

1.

Remove main fuse.

2.

See

Figure 6-102

. Disconnect VSS harness connector

[65A] (1) from VSS (3) mounted on rear of engine case
below starter motor assembly.

3.

Remove screw (2). Carefully remove VSS and O-ring from
engine crankcase.

1

2

3

sm01280

1. VSS connector [65]
2. Screw
3. VSS

Figure 6-102. VSS: All Models (XL shown)

INSTALLATION

TORQUE VALUE

FASTENER

10.2-13.6 Nm

90-120

in-lbs

VSS screw

NOTE

The new VSS O-ring has a teflon coating that provides lubric-
ation during installation. No other lubrication is needed.

1.

See

Figure 6-102

. Carefully install VSS (3) and O-ring into

engine crankcase with screw (2). Tighten to 90-120

in-lbs

(10.2-13.6 Nm).

2.

Attach VSS harness connector [65A] (1) to VSS.

3.

Install main fuse.

4.

Test ride the motorcycle.

HOME

2013 Sportster Service: Electrical 6-67

5.

After belt deflection and wheel alignment are properly
adjusted,

a.

Tighten axle nut (4) to 95-105 ft-lbs (129-142 Nm).
Install

new

E-clip (1).

b.

XL Models:

See

Figure 1-33

. Reposition clamp (3)

on rear brake line (2) and secure clamp to rear fork
(1) with screw (4). Tighten to 30-40

in-lbs

(3.4-4.5

Nm).

3

3

2

4

1

5

sm01443

1. Rear fork
2. Rear brake line
3. Clamp
4. Screw
5. Rear brake caliper

Figure 1-33. Rear Brake Line: XL Models

2

1

3

6

5

4

sm03591d

1. E-clip
2. Axle adjuster nut (2)
3. Axle adjuster (2)
4. Axle nut
5. Washer
6. Protective cap (2)

Figure 1-34. Drive Belt Adjustment: XL Models

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1-34 2013 Sportster Service: Maintenance

1.13

THROTTLE CONTROL

CABLE INSPECTION AND LUBRICATION

TORQUE VALUE

FASTENER

4.0-5.1 Nm

35-45

in-lbs

Switch housing screw

1.

Release the throttle cable tension. See

1.13 THROTTLE

CONTROL, Cable Adjustment

.

2.

See

Figure 1-35

. Remove screws (1) to separate the upper

switch housing from the lower housing.

3.

Unhook ferrules and cables from throttle grip. Remove
throttle sleeve.

4.

Inspect each cable. Replace cable assembly if cable is
frayed or kinked.

5.

Inspect cable outer sheath from throttle grip to induction
module. Replace if necessary.

6.

Apply a light coat of graphite to handlebar. Replace throttle
grip.

7.

Pour two drops of HARLEY LUBE into the cable housings.

8.

Install switch housing. Tighten to 35-45

in-lbs

(4.0-5.1

Nm).

9.

Adjust throttle cables.

CABLE ADJUSTMENT

Operation

Before starting engine, be sure throttle control will snap
back to idle position when released. A throttle control that
prevents engine from automatically returning to idle can
lead to loss of control, which could result in death or ser-
ious injury. (00390a)

1.

Back off the friction screw.

2.

Roll on and release the throttle grip. If the throttle does
not return to closed (idle), inspect and adjust throttle
cables.

3.

With engine idling, turn handlebar stop to stop. If engine
speed changes, adjust throttle cables.

Adjustment

1.

See

Figure 1-35

. Loosen throttle friction screw (3).

2.

Slide rubber boot off control cable adjusters (6).

3.

Loosen jamnuts (7).

4.

Turn cable adjusters to shorten cable housings to minimum
length.

5.

Point front wheel straight ahead. With engine OFF, gently
turn throttle control grip (2) to fully open. Hold in position.

6.

Gently turn adjuster (6) on throttle control cable (4) coun-
terclockwise until throttle cam (8) touches throttle cam
stop (10). Release throttle grip. Turn adjuster counterclock-

wise an additional 1/2-1 turn. Tighten jamnut on throttle
cable adjuster.

7.

Turn handlebar to right stop. Turn adjuster (6) on idle
control cable (5) to lengthen sleeve until end of cable
housing touches spring (9) within cable guide (11).

NOTE

Verify that throttle wheel returns to idle each time throttle grip
is released.

8.

Check adjustment. Twist and release throttle grip two or
three times. If throttle does not return to idle, turn idle
adjuster to shorten sleeve until correct. Tighten jamnuts.

9.

Slide the rubber boots over the cable adjusters.

4

4

5

2

9

5

3

11

1

10

8

6

7

sm01645b

1. Screw (2)
2. Throttle grip
3. Friction screw
4. Throttle (pull open) cable
5. Idle (pull close) cable
6. Cable adjuster (2)
7. Jamnut (2)
8. Throttle cam
9. Spring
10. Throttle cam stop
11. Cable guide

Figure 1-35. Throttle Cable Adjustment (typical)

HOME

2013 Sportster Service: Maintenance 1-35

1.14

CABLE AND CHASSIS LUBRICATION

GENERAL

Inspect

and

lubricate

the

following

items

according

to

1.5 MAINTENANCE SCHEDULE

.

•

Front brake hand lever

•

Clutch hand lever

•

Throttle control cables

•

Throttle control grip sleeve

•

Clutch cable

•

Foot shift lever pivot (if applicable)

•

Rear brake lever pivot

•

Steering head bearings

•

Jiffy stand

If service is on muddy or dusty roads, clean and lubricate at
shorter intervals.

CABLES AND HAND LEVERS

For throttle cables, see

2.28 THROTTLE CABLES: ALL

MODELS

.

Use HARLEY® LUBE for clutch lever and cable.

Use G40M BRAKE GREASE on front brake lever pin pivot hole
and on the end of piston that contacts brake lever.

FOOT SHIFT LEVER AND REAR BRAKE
PEDAL

Clean and lubricate the foot shift lever pivot (on models with
forward controls) and rear brake pedal pivot with ANTI-SEIZE
LUBRICANT at scheduled service intervals as specified in

1.5 MAINTENANCE SCHEDULE

.

If service is on muddy or dusty roads, clean and lubricate
components at shorter intervals.

JIFFY STAND

Clean and lubricate the jiffy stand. For more information, see

2.38 JIFFY STAND

.

STEERING HEAD BEARINGS

Lubricate the steering head bearings with SPECIAL PURPOSE
GREASE. See

1.19 STEERING HEAD BEARINGS

.

HOME

1-36 2013 Sportster Service: Maintenance

1.15

BRAKES

GENERAL

The front and rear brakes are fully hydraulic disc brake systems
that require little maintenance.

Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTES

•

If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Cover handlebar switches with a shop towel before adding
brake fluid to front master cylinder reservoir. Spilling brake
fluid on handlebar switches may render them inoperative.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

BRAKE LINES

Inspect brake lines for leaks, contact or abrasion. Refer to

Table 1-14

.

Table 1-14. Brake Line Inspection

REMEDY

INSPECTION

LINE TYPE

OK/Monitor

No marks

Steel lines

Slight mark in paint or plating*

Copper colored-paint/plating worn off*

Silver colored base material-no noticeable feel of wear*

Replace

Silver colored base material-noticeable feel of wear*

Brake fluid leak or other damage

OK/Monitor

No marks

Rubber hose

Slight dent or flattening of ribs*

Replace

Worn to bottom of ribs

Brake fluid leak or other damage

OK/Monitor

No marks

Protective cover
(steel, rubber, plastic or braided)

Slight dent in covering*

Slight dent or flattening of plastic covering*

Replace

Worn or cut-through covering-exposed brake line material

Brake fluid leak or other damage

* If there is line contact, reposition the line. If base material is visible, prevent corrosion with touch-up paint.

FLUID LEVEL

1.

Front brake:

Position vehicle on a flat level surface. Turn

handlebar so front brake master cylinder is approximately
level. See

Figure 1-36

.

2.

Check for fluid through reservoir sight glass.

NOTE

XL Models: See

Figure 1-37

. Rear brake reservoir cover may

be removed to more easily verify fluid level in reservoir.

HOME

2013 Sportster Service: Maintenance 1-37

3.

Rear brake:

Prepare vehicle:

a.

Have an assistant hold vehicle upright on a level
surface.

b.

See

Figure 1-38

or

Figure 1-39

. Check that fluid level

is between upper (3) and lower (4) marks on reservoir
sight window.

4.

If fluid is not visible through sight glass (front) or level in
sight window is low (rear), check system for leaks. Check
that brake pads are properly installed and not worn beyond
service wear limits. Perform any necessary repairs. See

1.16 BRAKE PADS AND DISCS: XL MODELS

or

1.17 BRAKE PADS AND DISCS: XR 1200X

.

5.

If fluid is still not visible through sight glass (front) or level
in sight window is low (rear), remove cover to verify fluid
level. If necessary, add DOT 4 BRAKE FLUID. Replace
cover. See

2.17 BLEEDING BRAKES

.

6.

Front brake hand lever and rear brake foot pedal must
have a firm feel when applied. If not, bleed system using
only DOT 4 BRAKE FLUID. See

2.17 BLEEDING

BRAKES

.

NOTE

XL Models: Replace rear brake reservoir cover if removed.

sm06942

Figure 1-36. Master Cylinder Sight Glass (typical)

pd00095a

Figure 1-37. Rear Brake Master Cylinder Reservoir Cover

(typical)

2

1

3

4

sm07317

1. Reservoir
2. Reservoir cap
3. Upper fluid level
4. Lower fluid level

Figure 1-38. Rear Brake Master Cylinder Reservoir: XL

Models

HOME

1-38 2013 Sportster Service: Maintenance

2

1

3

4

sm05262a

1. Reservoir
2. Reservoir cap
3. Upper fluid level
4. Lower fluid level

Figure 1-39. Rear Brake Master Cylinder Reservoir: XR

1200X

TROUBLESHOOTING

Use the following troubleshooting guide to help in determining
probable causes of poor brake operation. Refer to

Table 1-15

.

Table 1-15. Troubleshooting Brakes

REMEDY

CHECK FOR

CONDITION

Bleed brake system.

Air in system

Excessive lever or pedal
travel or spongy feel

Fill master cylinder reservoir with approved brake
fluid. Bleed brake system.

Master cylinder reservoir low on fluid

Replace brake pads.

Worn brake pads

Chattering sound when brake
is applied

Tighten bolts.

Loose mounting bolts

Replace brake disc.

Warped brake disc

Fill master cylinder reservoir with approved brake
fluid and bleed brake system.

Low fluid level

Ineffective brake lever or
pedal - travels to limit

Rebuild master cylinder.

Piston cup not functioning

Replace brake disc.

Distorted or glazed brake disc

Ineffective brake lever or
pedal - travel normal

Replace brake pads.

Distorted, glazed or contaminated brake pads

Inspect master cylinder.

Cup in master cylinder blocking relief port

Brake pads drag on disc - do
not retract.

Correct fluid level.

Master cylinder overfilled

HOME

2013 Sportster Service: Maintenance 1-39

1.16

BRAKE PADS AND DISCS: XL MODELS

INSPECTION

Brake Pads

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

See

Figure 1-40

. Replace brake pads if brake pad friction

material on either the front or rear caliper is worn to 0.04 in
(1.02 mm) or less (3) above the backing plate. Always replace
both pads in a caliper as a set. See

1.16 BRAKE PADS AND

DISCS: XL MODELS, Brake Pad Replacement: Front

or

1.16 BRAKE PADS AND DISCS: XL MODELS, Brake Pad
Replacement: Rear

.

When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage or leakage.

1

2

3

sm07224

1. Front, from below
2. Rear, from above
3. MIN thickness

Figure 1-40. XL Brake Pad MIN Thickness

Brake Disc Thickness, Lateral Runout and
Warpage

See

Figure 1-41

. The minimum brake disc thickness is stamped

on the side of the disc. Replace disc if worn past minimum
thickness or badly scored.

Maximum brake disc lateral runout and warpage is 0.008 in
(0.2 mm) when measured near the outside diameter.

•

To replace front brake disc(s), see

2.5 WHEELS, Front

Wheel

.

•

To replace rear brake disc, see

2.5 WHEELS, Rear Wheel

.

HOME

1-40 2013 Sportster Service: Maintenance

4

4

5

1

3

3

2

2

4

4

3

3

sm01427

1. Front brake caliper (from below)
2. Brake disc
3. Brake pad
4. Brake pad backing plate
5. Rear brake caliper (from rear)

Figure 1-41. Brake Pads and Discs

BRAKE PAD REPLACEMENT: FRONT

TORQUE VALUE

FASTENER

14.8-19.6 Nm

131-173

in-lbs

Brake pad pin

2.0-2.9 Nm

18-25

in-lbs

Brake pad pin plug

1.0-2.0 Nm

9-17

in-lbs

Brake master cylinder, front,
reservoir cover screws

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTES

•

Do not remove front caliper(s) from mounting bracket
unless caliper mounting pins require service. Caliper
removal increases risk of contaminate damage.

•

If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Cover handlebar switches with a shop towel before adding
brake fluid to front master cylinder reservoir. Spilling brake
fluid on handlebar switches may render them inoperative.

1.

Position motorcycle so that front master cylinder reservoir
is level.

2.

See

Figure 1-42

. Remove two screws (5), reservoir cover

(4), diaphragm plate (3) and diaphragm (2) from master
cylinder reservoir (1).

3.

Wrap a shop towel around the master cylinder reservoir
to contain any brake fluid spills.

NOTE

As the pistons are pushed back into the caliper, fluid level may
rise higher than fluid level mark at about 1/4 in (6.35 mm) below
top of reservoir. You may have to remove fluid to allow for this.

4.

Press against the side of the brake caliper body to push
the outside brake pad (pad closest to caliper pistons) back.
This pushes the caliper pistons back into their bores.

HOME

2013 Sportster Service: Maintenance 1-41