Harley Davidson 2013 Sportster Models. Service Manual — page 28

FOOT CONTROLS: XL MID-MOUNT CONTROLS

5-6 2013 Sportster Service: Drive/Transmission

Apply 2-3 drops of LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to threads of
primary cover screws.

See

Figure 5-8

. Install primary cover and gasket using

sixteen screws with captive washers. Tighten to 100-120

in-lbs

(11.3-13.6 Nm) in sequence.

Install drain plug:

Clean the magnetic drain plug.

Inspect O-ring and replace if necessary.

Apply LOCTITE 565 PIPE SEALANT WITH TEFLON
to the drain plug.

Install plug. Tighten to 14-30 ft-lbs (19.0-40.7 Nm).

Install

new

O-ring over cable end fitting of clutch cable

lower section. Turn fitting clockwise to install into primary
cover. Tighten fitting to 36-108

in-lbs

(4.1-12.2 Nm).

Fit coupling over cable end with rounded side of coupling
inboard and ramp connector button outboard. With
retaining ring side of ramp assembly facing inward, place
hook of ramp around coupling button. Rotate assembly
counterclockwise until tang on inner ramp fits in slot of
primary cover.

Thread nut on adjusting screw assembly until slot of screw
is accessible with a screwdriver. Fit nut hex into recess of
outer ramp and turn adjusting screw counterclockwise
until resistance is felt. Back off adjusting screw 1/4 turn.

Slide lockplate and spring onto flats of adjusting screw. If
necessary, turn adjusting screw clockwise slightly until the
lockplate slides onto flats. Fit the lockplate within recess
of outer ramp.

10. Install the oil drain plug. Tighten the oil drain plug.

11. Fill transmission to specification.

12. Install

new

quad ring in groove of primary cover. Verify

that quad ring is fully seated in groove.

13. Install six screws to secure clutch inspection cover to

primary cover. Tighten in a crosswise pattern to 90-120

in-lbs

(10.3-13.6 Nm).

14. Adjust the clutch and the clutch lever free play. See

1.11 CLUTCH

15. Install left side rider footrest and mounting bracket

assembly.

Models with Mid-mount Controls:

See

2.40 RIDER

2.42 RIDER FOOT CONTROLS: XR 1200X

Models with Forward Controls:

See

2.41 RIDER

FOOT CONTROLS: XL FORWARD CONTROLS

16. Adjust primary chain free play. When tension is set, tighten

locknut to 20-25 ft-lbs (27.1-33.9 Nm). See

1.9 PRIMARY

CHAIN

17. Install rubber washer and gear shift lever on shifter shaft.

Secure with pinch screw and washer. Tighten to 16-20 ft-
lbs (21.7-27.1 Nm).

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

18. Install the battery cables.

sm07176

Figure 5-8. Outer Primary Cover Torque Sequence

2013 Sportster Service: Drive/Transmission 5-7

5.4

PRIMARY DRIVE AND CLUTCH: XL MODELS

TROUBLESHOOTING

Refer to

Table 5-4

Table 5-4. Clutch Troubleshooting

REMEDY

CAUSE

CHECK
ORDER

SYMPTOM

Check and adjust clutch release mechanism.

Incorrect clutch release adjustment

Clutch slips

Check service wear limits. Replace plates.

Worn clutch plates

Check and adjust clutch release mechanism.

Incorrect clutch release adjustment

Clutch drags

Replace release ramps and/or balls.

Worn clutch release ramps or balls

Replace clutch steel plates.

Warped clutch steel plates

Replace clutch gear or hub as required.

Worn or damaged clutch gear splines

Drain lubricant to correct level.

Overfilled primary

REMOVAL

TOOL NAME

PART NUMBER

SPORTSTER 5-SPEED SPROCKET
LOCKING LINK

HD-38362

PRIMARY DRIVE LOCKING TOOL

HD-46283

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)

NOTE

See

. If replacement of clutch pack (28) is the only

service work required, perform REMOVAL steps 1 and 4 only,
and then proceed to the NOTES under DISASSEMBLY.

Disconnect negative (-) battery cable from stud on engine
crankcase

behind

starter

motor

assembly.

See

Open left side cover. See

2.18 LEFT SIDE COVER

Remove positive (+) battery cable from battery positive
(+) terminal. See

Remove the primary cover. Discard the primary cover
gasket. See

5.3 PRIMARY COVER

NOTE

See

Figure 5-9

. Do not position the sprocket locking link too

close to the shifter shaft (2). If the sprocket locking link contacts
the shifter shaft the sprocket locking link may damage the
shifter shaft and/or the engine crankcase.

Install a locking link:

XL 883 Models:

Use SPORTSTER 5-SPEED

SPROCKET LOCKING LINK (Part No. HD-38362).

XL 1200 Models:

Use PRIMARY DRIVE LOCKING

TOOL (Part No. HD-46283).

Remove the engine sprocket nut. Do not remove engine
sprocket at this time.

See

. Remove large retaining ring (16).

Remove adjusting screw assembly (12, 13, 14 and 15)
from pressure plate (11).

NOTE

Transmission mainshaft nut (7) has left-hand threads. Turn nut
clockwise to loosen and remove from mainshaft.

Remove mainshaft nut (7) and spring washer (6).

Remove the clutch assembly, primary chain and engine
sprocket as an assembly from the vehicle.

10. Inspect primary chain. Replace if necessary.

11. Inspect stator and rotor. Replace if necessary. See

6.24 ALTERNATOR

sm01257a

1. Sprocket locking link
2. Shifter shaft

Figure 5-9. Using Sprocket Locking Link (Part No.

HD-46283 or HD-38362) to Loosen Engine Sprocket Nut

5-8 2013 Sportster Service: Drive/Transmission

sm01352

15.

Release plate

Retaining ring

16.

Clutch shell and sprocket

Retaining ring

17.

Diaphragm spring

Ball bearing

18.

Retaining ring

Spring seat

19.

Retaining ring

Clutch hub

20.

Spring washer

Retaining ring

21.

Inner ramp

Mainshaft nut

22.

Spring plate

Outer ramp

23.

Nut

Steel plate (6)

10.

24.

Friction plate, fiber (8)

Locking plate

25.

11.

Clutch adjustment spring

Pressure plate

12.

26.

Adjusting screw

Ball (3)

27.

13.

Clutch cable coupling

Bearing

14.

28.

Retaining ring

Clutch pack (consists of items 8, 9, 10)

Figure 5-10. Clutch Assembly: XL Models

2013 Sportster Service: Drive/Transmission 5-9

DISASSEMBLY

TOOL NAME

PART NUMBER

CLUTCH SPRING FORCING SCREW

HD-38515-91

SPRING COMPRESSING TOOL

HD-38515-A

NOTES

•

See

. If replacement of clutch pack (28) is the

only service work required, perform DISASSEMBLY Steps
2-5 and 7 only, and then proceed to the NOTE under
INSPECTION AND REPAIR.

•

Observe all WARNING and CAUTION statements which
apply to the steps specified.

See

. With clutch assembly removed from

primary chaincase, install the adjusting screw assembly
(12, 13, 14 and 15) into the pressure plate (11):

Match the two tabs on release plate (15) to the
notches in the pressure plate.

Install the retaining ring (16).

Disassemble clutch using a spring compressing tool. The
diaphragm spring is compressed and, if removed without
proper tools can fly out, which could result in death or
serious injury. (00292a)

See

Figure 5-11

. Compress clutch diagram spring.

Thread the CLUTCH SPRING FORCING SCREW
(Part No. HD-38515-91) onto the clutch adjusting
screw.

Place the bridge of the SPRING COMPRESSING
TOOL (Part No. HD-38515-A) against diaphragm
spring.

Thread the tool handle onto end of forcing screw.

NOTE

See

. Turn compressing tool handle only enough

to remove retaining ring (19) and spring seat (18). Excessive
compression of diaphragm spring could damage clutch pres-
sure plate.

See

. With a wrench on the clutch spring for-

cing screw flats to prevent the forcing screw from turning,
turn handle clockwise until tool relieves pressure on
retaining ring (19) and spring seat (18).

Remove and discard retaining ring. Remove spring seat
from the groove in clutch hub (5) prongs. Remove the
assembly of diaphragm spring (17), pressure plate (11),
adjusting screw components (12, 13, 14 and 15) and
compressing tool.

Turn the compressing tool handle counterclockwise until
the clutch spring forcing screw disconnects from the clutch
adjusting screw. Remove spring seat and diaphragm
spring from pressure plate assembly.

Remove retaining ring (16) and adjusting screw assembly
from pressure plate. If necessary, disassemble adjusting
screw assembly by removing retaining ring (14), and then

separating the remaining adjusting screw components
(12, 13, and 15).

Remove the clutch pack (28) from the clutch hub. The
clutch pack consists of one spring plate (8), six steel plates
(9), and eight friction (fiber) plates (10).

NOTE

See

. Bearing (3) will be damaged by disassembly

of clutch hub (5) and shell (2). Always replace bearing (3) if
hub and shell are disassembled. If the assembly is pressed
apart, the bearing must be replaced.

If necessary, disassemble clutch shell and clutch hub as
follows:

Remove retaining ring (1) from inboard end of clutch
hub (5).

Using an arbor press, separate clutch hub from
assembly of clutch shell (2), bearing (3), and retaining
ring (4).

Remove retaining ring (4) from groove in clutch shell.

Press on the inboard side of bearing (3) outer race
to remove bearing from clutch shell.

sm01261

1. Forcing screw
2. Bridge, spring compressing tool
3. Handle
4. Open-end wrench

Figure 5-11. Compressing Clutch Diaphragm Spring

INSPECTION AND REPAIR: XL MODELS

NOTE

See

. If replacement of clutch pack (28) is the only

service work required, perform all INSPECTION AND REPAIR
steps (except Step 2f), and then proceed to the NOTES under
ASSEMBLY.

5-10 2013 Sportster Service: Drive/Transmission

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)

See

. Wash all parts, except the friction plates

(10) and bearings (3 and 13), in a non-volatile cleaning
solution or solvent. Blow parts dry with low pressure
compressed air.

Examine the clutch components as follows:

Inspect all clutch plates for wear and discoloration.

Inspect all friction plates (10) for worn lining surfaces
or checked or chipped linings.

Inspect each steel plate (9) for grooves.

Place each steel plate on a flat surface. Using a feeler
gauge, check for flatness in several places. If any one
of the plates are damaged, or warped more than 0.006
in (0.15 mm), replace the entire clutch pack.

Wipe the lubricant from the seven wide friction plates.

See

Figure 5-12

. Measure the thickness of each fric-

tion plate. If any one of the plates is less than 0.0795
in (2.02 mm), replace the entire clutch pack.

See

. Inspect clutch shell ball bearing (3)

for smoothness by rotating clutch shell while holding
clutch hub. If bearing is rough or binds, it must be
replaced.

See

Figure 5-13

. Check the primary chain sprocket

(3) and the starter ring gear (4) on the clutch shell (1).
If either sprocket or ring gear are badly worn or dam-
aged, replace the clutch shell.

Check the slots (5, 6) that mate with the clutch plates
on both clutch shell and clutch hub (2). If slots are
worn or damaged, replace shell and/or hub.

See

. Check the diaphragm spring (17)

for cracks or bent tabs. Install a

new

spring if either

condition exists.

sm07238

Figure 5-12. Friction Plate Thickness

sm01263b

1. Clutch shell
2. Clutch hub
3. Primary chain sprocket
4. Starter ring gear
5. Clutch hub slots
6. Clutch shell slots

Figure 5-13. Checking Clutch Hub and Clutch Shell

2013 Sportster Service: Drive/Transmission 5-11

ASSEMBLY

TOOL NAME

PART NUMBER

CLUTCH SPRING FORCING SCREW

HD-38515-91

SPRING COMPRESSING TOOL

HD-38515-A

NOTES

•

See

. If replacement of clutch pack (28) is the

only service work required, perform all ASSEMBLY Steps
except 2, 5 and 6, and then proceed to the NOTE under
INSTALLATION.

•

Replace the clutch pack, steel plates, friction plates and
spring plate, as a set.

Submerge and soak all friction and steel plates in
GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMIS-
SION AND PRIMARY CHAINCASE LUBRICANT for at
least five minutes.

See

Figure 5-14

. Assemble the clutch hub (1) and clutch

shell (4):

Press a

new

ball bearing (3) into clutch shell.

Secure the bearing with a

new

retaining ring (2).

Press inboard end of clutch hub into clutch shell
bearing.

Secure with a

new

retaining ring (5) on end of hub.

sm01354

1. Clutch hub
2. Retaining ring
3. Ball bearing
4. Clutch shell
5. Retaining ring

Figure 5-14. Clutch Hub and Shell Assembly

NOTE

See

. The clutch pack (28) consists of one spring

plate (8), six steel plates (9) and eight friction (fiber) plates
(10).

Install clutch pack into clutch shell in order:

F - St - F - St - F - St - F - Sp - F - St - F - St - F - St - F

(

= Friction plate,

= Steel plate,

= Spring plate)

Place pressure plate (11) and adjusting screw onto clutch
pack (28).

Assemble bearing (13) and adjusting screw (12) in release
plate (15). Secure with

new

retaining ring (14).

Align the two tabs on perimeter of release plate (15) with
the corresponding recesses in pressure plate. Install
adjusting screw assembly (12, 13, 14, 15) into pressure
plate (11). Secure adjusting screw assembly with

new

retaining ring (16).

Install diaphragm spring (17) with its concave side facing
inboard (toward pressure plate), onto pressure plate
assembly. Align square openings of pressure plate and
diaphragm spring (17).

Position spring seat (18) with its flat, larger outer diameter
side facing inboard (toward diaphragm spring).

Install a

new

retaining ring (19) onto convex (outboard)

side of diaphragm spring.

10. Thread the CLUTCH SPRING FORCING SCREW (Part

No. HD-38515-91) onto the clutch adjusting screw. Place
the bridge of the SPRING COMPRESSING TOOL (Part
No. HD-38515-A) against diaphragm spring. Thread the
tool handle onto end of forcing screw. Do not tighten
compressing tool against diaphragm spring at this time.

11. See

Figure 5-11

. Place an open-end wrench (4) on the

clutch spring forcing screw (1) flats to prevent the forcing
screw from turning.

NOTE

Turn compressing tool handle only enough to install spring
seat and retaining ring. Excessive compression of diaphragm
spring could damage clutch pressure plate.

12. See

. Turn compressing tool handle clockwise

to compress diaphragm spring (17). Compresses just
enough to install spring seat (18) and retaining ring (19)
into the groove in clutch hub (5) prongs.

13. Verify retaining ring is positioned against flange face

(outboard side) of spring seat and fully seated in groove
of clutch hub. Carefully loosen and remove compressing
tool.

NOTE

As the compressing tool is removed, the diaphragm spring will
move outward. This movement will force the spring seat up
into the inside of the retaining ring. The spring seat provides
an operating surface for the diaphragm spring. Additionally, it
prevents the retaining ring from coming out during operation.

5-12 2013 Sportster Service: Drive/Transmission

INSTALLATION

TOOL NAME

PART NUMBER

SPORTSTER 5-SPEED SPROCKET
LOCKING LINK

HD-38362

PRIMARY DRIVE LOCKING TOOL

HD-46283

TORQUE VALUE

FASTENER

326-353 Nm

240-260 ft-lbs

Engine sprocket nut: XL
Models

67.8-81.3 Nm

50-60 ft-lbs

Transmission mainshaft nut:
XL Models

NOTE

See

. If replacement of clutch pack (28) is the only

service work required, perform INSTALLATION last step only.

See

. Remove retaining ring (16). Remove

adjusting screw assembly (12, 13, 14, 15) from pressure
plate (11). This allows installation of the transmission
mainshaft nut and washer.

Clean the oil off the threads of the engine sprocket shaft,
the engine sprocket nut, the transmission mainshaft and
the mainshaft nut.

Install the engine sprocket, primary chain and clutch
assembly as a unit.

NOTE

See

Figure 5-15

. Do not position the sprocket locking link too

close to the shifter shaft (2). If the sprocket locking link contacts
the shifter shaft while tightening the engine sprocket nut, the
shifter shaft and/or the engine crankcase may be damaged.

See

Figure 5-15

. Install the sprocket locking link.

XL 883 Models:

Use the SPORTSTER 5-SPEED

SPROCKET LOCKING LINK (Part No. HD-38362).

XL 1200 Models:

Use the PRIMARY DRIVE

LOCKING TOOL (Part No. HD-46283).

Apply two or three drops of LOCTITE 262 HIGH
STRENGTH THREADLOCKER AND SEALANT (red) onto
threads of engine sprocket shaft.

Install engine sprocket nut. Tighten to 240-260 ft-lbs (326-
353 Nm).

NOTE

See

Figure 5-16

. Washer (2) must be installed with the word

"out" facing the transmission mainshaft nut (1). Incorrect
assembly can result in clutch and/or transmission failure.

See

Figure 5-16

. Apply two or three drops of LOCTITE

262 HIGH STRENGTH THREADLOCKER AND SEALANT
(red) onto threads of transmission mainshaft. Install spring
washer (2) and mainshaft nut (1) (left-hand threads) on
transmission mainshaft. Tighten nut to 50-60 ft-lbs (67.8-
81.3 Nm).

Remove the sprocket locking link.

See

Figure 5-17

. Install adjusting screw assembly (1) in

pressure plate, noting that two tabs on perimeter of release
plate must be inserted into corresponding recesses in

pressure plate. Secure assembly with a

new

retaining ring

(2).

10. Install primary cover using

new

gasket. See

5.3 PRIMARY

COVER

11. Adjust primary chain and clutch. See

1.9 PRIMARY CHAIN

and

1.11 CLUTCH

12. Fill transmission with GENUINE HARLEY-DAVIDSON

FORMULA+ TRANSMISSION AND PRIMARY CHAIN-
CASE LUBRICANT. See

1.10 TRANSMISSION LUB-

RICANT

13. Connect battery and close left side cover. See

1.22 BAT-

TERY MAINTENANCE

sm06563

1. Sprocket locking link
2. Shifter shaft

Figure 5-15. Tighten Engine Sprocket Fastener (typical)

sm01355

1. Mainshaft nut
2. Spring washer
3. Clutch hub

Figure 5-16. Mainshaft Nut and Washer

2013 Sportster Service: Drive/Transmission 5-13

sm01268a

1. Adjusting screw assembly
2. Retaining ring

Figure 5-17. Clutch Adjusting Screw Assembly and

Retaining Ring

5.4 PRIMARY DRIVE AND CLUTCH: XL MODELS,

5-14 2013 Sportster Service: Drive/Transmission

5.5

PRIMARY DRIVE AND CLUTCH: XR 1200X

TROUBLESHOOTING

See

Troubleshooting

REMOVAL

TOOL NAME

PART NUMBER

SPORTSTER 5-SPEED SPROCKET
LOCKING LINK

HD-38362

PRIMARY DRIVE LOCKING TOOL

HD-46283

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)

Disconnect negative (-) battery cable from stud on engine
crankcase

behind

starter

motor

assembly.

See

Open left side cover. See

2.18 LEFT SIDE COVER

Remove positive (+) battery cable from battery positive
(+) terminal. See

CLUTCH: XR 1200X, Installation

Remove primary cover and discard primary cover gasket.
See

5.3 PRIMARY COVER

NOTES

•

See

Figure 5-18

. Make sure not to position the sprocket

locking link (1) too close to the shifter shaft (2). Contact
between sprocket locking link and shifter shaft during
engine sprocket bolt removal will cause damage to the
surrounding assemblies.

•

The engine sprocket bolt is a single-use fastener. Discard
and replace with a new bolt upon removal.

•

Japanese models require PRIMARY DRIVE LOCKING
TOOL (Part No. HD-46283).

Install SPORTSTER 5-SPEED SPROCKET LOCKING
LINK (Part No. HD-38362). Remove and discard the

engine sprocket bolt. Do not remove engine sprocket at
this time.

See

Figure 5-19

. Remove large retaining ring (12).

Remove adjusting screw assembly (13, 14, 15 and 16)
from pressure plate (17).

NOTE

Transmission mainshaft nut (23) has left-hand threads. Turn
nut clockwise to loosen and remove from mainshaft.

Remove nut (23) and spring washer (24). Remove the
clutch assembly, primary chain and engine sprocket from
the vehicle as an assembly.

Inspect primary chain. Replace as necessary.

Inspect stator and rotor. See

6.24 ALTERNATOR

. Replace

damaged parts as necessary.

NOTE

If replacement of primary chain is the only service work
required, proceed directly to

5.5 PRIMARY DRIVE AND

. Skip Step 1 of that procedure

and begin with the NOTE preceding Step 2.

sm01257a

1. Sprocket locking link
2. Shifter shaft

Figure 5-18. Loosen Engine Sprocket Bolt

2013 Sportster Service: Drive/Transmission 5-15

sm00278

21.

11.

Damper spring

Diaphragm spring

Spring

22.

12.

Lockplate

Damper spring seat

Retaining ring

13.

23.

Release plate

Nut

Mainshaft nut

24.

14.

Washer

Retaining ring

Outer ramp

25.

15.

Coupling

Clutch hub

Bearing

16.

26.

Adjusting screw

Ball (3)

Inner thrust washer

27.

17.

Needle bearing inner race

Pressure plate

Inner ramp

28.

18.

Retaining ring

Needle bearing

Friction plate, fiber (7)

19.

29.

Steel plate (7)

Retaining ring

Clutch shell and sprocket

30.

20.

10.

Outer thrust washer

Friction plate, narrow, fiber

Spring seat

Figure 5-19. Clutch Assembly: XR 1200X

5.5 PRIMARY DRIVE AND CLUTCH:

5-16 2013 Sportster Service: Drive/Transmission

DISASSEMBLY

TOOL NAME

PART NUMBER

CLUTCH SPRING FORCING SCREW

HD-38515-91

SPRING COMPRESSING TOOL

HD-38515-A

See

Figure 5-19

. With clutch assembly removed from

primary chaincase, install adjusting screw assembly (13,
14, 15 and 16) into pressure plate (17):

Match the two tabs on perimeter of release plate (13)
to the notches in pressure plate.

Install the retaining ring (12).

Disassemble clutch using a spring compressing tool. The
diaphragm spring is compressed and, if removed without
proper tools can fly out, which could result in death or
serious injury. (00292a)

Assemble the compressing tool:

Thread the CLUTCH SPRING FORCING SCREW
(Part No. HD-38515-91) onto the clutch adjusting
screw.

Place the bridge of SPRING COMPRESSING TOOL
(Part No. HD-38515-A) against diaphragm spring.

Thread the tool handle onto end of forcing screw.

NOTE

Excessive compression of diaphragm spring could damage
clutch pressure plate.

With a wrench on the clutch spring forcing screw flats to
prevent the forcing screw from turning, turn handle clock-
wise until tool relieves pressure on retaining ring (9) and
spring seat (10).

Remove and discard retaining ring. Remove spring seat
from the groove in clutch hub prongs. Remove the dia-
phragm spring (11), pressure plate (17), adjusting screw
components (13, 14, 15 and 16) and compressing tool as
an assembly.

Remove retaining ring (12) and adjusting screw assembly
from pressure plate. If necessary, disassemble adjusting
screw assembly. See

XR 1200X, Adjusting Screw

Remove the clutch pack from the clutch hub. The clutch
pack consists of seven friction (fiber) plates (18), seven
steel plates (19), one narrow friction plate (20), one
damper spring (21) and one seat (22).

ADJUSTING SCREW

See

Figure 5-20

. Remove adjusting screw assembly.

Remove large retaining ring (1).

Remove adjusting screw assembly from pressure
plate (9).

If necessary, disassemble adjusting screw assembly.

Remove and discard small retaining ring (6).

Separate the adjusting screw (8) from the bearing (7)
and release plate (5).

Remove bearing (7) from release plate (5).

Replace components as required and reassemble
adjusting screw assembly in reverse order.

Install adjusting screw assembly into pressure plate.

See

Figure 5-35

. Align two tabs on perimeter of

release plate with corresponding recesses (3) in
pressure plate.

Secure the adjusting screw assembly with

new

retaining ring.

sm00281

1. Retaining ring
2. Spring seat
3. Diaphragm spring
4. Retaining ring
5. Release plate
6. Retaining ring
7. Bearing
8. Adjusting screw
9. Pressure plate

Figure 5-20. Adjusting Screw Assembly

CLUTCH PACK CLEANING AND
INSPECTION

Steel Plates

Wash the steel plates, and the damper spring and seat in
solvent.

5.5 PRIMARY DRIVE AND CLUTCH: XR 1200X, Adjusting
Screw

2013 Sportster Service: Drive/Transmission 5-17

See

Figure 5-21

. Inspect each steel plate.

Check for wear, grooves, or discoloration.

Gauge warpage around the plate. If warpage exceeds
specifications, replace the entire clutch pack. Refer
to

Table 5-5

Inspect the damper spring and the spring seat. Replace
as required.

sm07239

Figure 5-21. Gauging a Steel Plate

Friction Plates

NOTE

Do not wash the friction plates in solvent.

Wipe the friction plates clean of lubricant.

See

Figure 5-22

. Inspect each friction plate.

Check for wear or discoloration.

Measure the seven friction plates. If one thickness is
less than specified, replace the entire clutch pack.
Refer to

Table 5-5

sm07238

Figure 5-22. Friction Plate Thickness

Table 5-5. Clutch Pack Plate Specifications

SERVICE WEAR LIMIT

ITEM

CLUTCH PLATE THICKNESS

2.0200

0.0795

Friction plate (fiber)

N/A

Steel plate

MAXIMUM ALLOWABLE WARPAGE

0.1500

0.0059

Friction plate (fiber)

0.1500

0.0059

Steel plate

CLUTCH SHELL/HUB INSPECTION

Inspect engine sprocket for damage or excessive wear.
Replace as required.

Disassemble adjusting screw assembly and inspect
bearing, release plate, and adjusting screw. See

Remove clutch hub from clutch shell. Inspect primary chain
sprocket and the starter ring gear on the clutch shell.

Inspect slots that mate with the clutch plates on both clutch
shell and hub.

See

Figure 5-23

. Inspect the clutch shell compensating

spring set.

NOTE

It is possible for the compensating springs to float and move
during inspection. This condition is normal.

See

Figure 5-24

. Inspect clutch shell needle bearing for

smoothness. Rotate the clutch shell while holding the
clutch hub. If bearing is rough or binds, it must be replaced.

5.5 PRIMARY DRIVE AND CLUTCH: XR 1200X,

5-18 2013 Sportster Service: Drive/Transmission

See

Clutch Shell Bearing Replacement

See

Figure 5-25

. Inspect clutch shell bearing inner race

on the back side of the clutch hub for pitting and wear. If
the inner race shows any signs of damage, the complete
hub assembly must be replaced.

Replace damaged parts as necessary.

sm00291a

Figure 5-23. Compensating Spring Set

sm00292a

Figure 5-24. New Needle Bearing in Clutch Shell

sm00293a

Figure 5-25. Clutch Hub Bearing Race

CLUTCH SHELL BEARING REPLACEMENT

TOOL NAME

PART NUMBER

CLUTCH SHELL BEARING
REMOVER/INSTALLER

B-45926

NOTE

The clutch shell uses a caged needle bearing that corresponds
to an inner race installed on the clutch hub.

See

Figure 5-27

. Place clutch shell on support blocks with

sprocket side facing up.

NOTE

The CLUTCH SHELL BEARING REMOVER/INSTALLER (Part
No. B-45926) is clearly marked for removal and installation
purposes.

See

Figure 5-27

. Insert removal end of tool into bearing

assembly and remove bearing from clutch shell.

See

Figure 5-28

. Remove bearing guide from end of

CLUTCH SHELL BEARING REMOVER/INSTALLER (Part
No. B-45926).

Place

new

needle bearing onto installer end of tool and

insert the bearing guide.

See

Figure 5-29

. Place clutch shell on support blocks with

sprocket side facing up.

Press bearing into clutch shell until tool bottoms on the
shell. This will be the correct installed height.

2013 Sportster Service: Drive/Transmission 5-19

6.27

MAIN WIRING HARNESS

WIRE HARNESS CONNECTORS

See

Figure 6-104

Figure 6-105

Figure 6-106

. The main

wiring harness can be divided up into four bundles, originating
at the ECM caddy (XL models) or H-bracket (XR 1200X) (1).
These bundles are:

Lower left bundle (2)

including:

•

Rear stop lamp switch wires [121B],

•

Crankcase ground [GND1],

•

Fuel pump connector [141A],

•

Siren connector [142B],

•

TSM/TSSM/HFSM connector [30B],

•

Main fuse holder [5],

•

Data link connector [91A],

•

Rear oxygen (O2) sensor connector [137B].

Lower right bundle (3)

including:

•

Vehicle speed sensor (VSS) connector [65B],

•

Green starter motor wire [128B],

•

Engine Temperature (ET) sensor connector [90B].

Upper rear bundle (4)

including:

•

ECM connector [78B],

•

Engine sub-harness connector [145A],

•

P&A battery connector [160B],

•

Rear lighting sub-harness connector [7A],

•

Fuel sender resistor assembly/connector [200].

Upper front bundle (5)

including:

•

Hand control connectors [22B], [24B],

•

Headlamp connector [38A],

•

Front turn signal connector [31A],

•

Instruments connector [20B],

•

Horn wires [122B],

•

Ignition switch [33],

•

Coil connector [83B],

•

Neutral switch connector [136B],

•

Oil pressure switch connector [120B],

•

Crank position (CKP) sensor connector [79B],

•

Front oxygen (O2) sensor connector [138B],

•

Voltage regulator DC output connector [77B].

sm07539

1. ECM caddy
2. Lower left bundle
3. Lower right bundle
4. Upper rear bundle
5. Upper front bundle
6. Front view
7. Rear view

Figure 6-104. Main Wiring Harness: XL Models

2013 Sportster Service: Electrical 6-69

sm07541

1. H-bracket
2. Lower left bundle
3. Lower right bundle
4. Upper rear bundle
5. Upper front bundle

Figure 6-105. Main Wiring Harness, Front: XR 1200X

sm07542

1. H-bracket
2. Lower left bundle
3. Lower right bundle
4. Upper rear bundle
5. Upper front bundle

Figure 6-106. Main Wiring Harness, Rear: XR 1200X

REMOVAL

To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.4 FUEL TANK: XL MODELS

4.5 FUEL TANK: XR

1200X

Remove seat.