Harley Davidson 2013 Sportster Models. Service Manual — page 10
1.21
ENGINE MOUNTS AND STABILIZER LINKS
INSPECTION
Check engine mounts and stabilizer links as follows:
1.
See
. Check for cracks or tears in engine mount
isolator rubber (17, 18).
2.
Check for lateral movement at each end of the three sta-
bilizer links (8). Any lateral movement indicates the need
to replace the stabilizer link. Rotational movement does
not indicate excess wear.
3.
Check that all engine mount bolts and stabilizer link screws
are tight. See
, or
for torque specifications.
4.
Check that the mounts are supporting the weight of the
motor.
20
4
15
3
4
5
15
8
12
4
9
17
11
6
3
4
19
8
20
18
14
1
18
10
13
16
4
8
7
2
5
sm03285
15.
8.
1.
Stabilizer link bracket (2)
Stabilizer link (3)
Screw (3)
2.
16.
9.
Screw (2)
Engine bracket
Front isolator mount
10.
3.
17.
Rear isolator mount
Screw (3)
Front mount isolator (2)
18.
11.
4.
Rear mount isolator (2)
Nut
Screw (11)
5.
19.
12.
Washer (4)
Grounding strap
Bolt
13.
6.
20.
Rear fork pivot shaft
Spacer
Rear fork pivot bolt (2)
14.
7.
Rear pivot lockplate
Lockwasher (2)
Figure 1-66. Engine Mounting Assemblies: All Models (typical)
1-58 2013 Sportster Service: Maintenance
1.22
BATTERY MAINTENANCE
GENERAL
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)
Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)
Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth
defects or other reproductive harm. Wash hands after
handling. (00019e)
Keep battery clean and lightly coat terminals with petro-
leum jelly to prevent corrosion. Failure to do so could
result in damage to battery terminals. (00217a)
AGM batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries. The
batteries are shipped pre-charged and ready to be put into
service. Do not attempt to open these batteries for any reason.
NOTE
For charging information, see
. For testing information, see the electrical
diagnostic manual.
3
4
2
1
sm03272
1. Warning label
2. Positive (+) terminal
3. Negative (-) terminal
4. Warranty/date code label
Figure 1-67. Battery
1
2
3
4
5
6
om00618
4.
1.
Keep flames away
Contents are corrosive
2.
5.
Wear safety glasses
Read instructions
6.
3.
Keep away from children
Contents are explosive
Figure 1-68. Battery Warning Label
2013 Sportster Service: Maintenance 1-59
Table 1-21. Antidotes for Battery Acid
TREATMENT
CONTACT
Flush with water.
External
Drink large quantities of milk or water, followed
by milk of magnesia, vegetable oil or beaten
eggs. Get immediate medical attention.
Internal
Flush with water. Get immediate medical
attention.
Eyes
BATTERY DISCONNECTION AND REMOVAL
Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
1.
Open left side cover.
NOTE
Models with sirens: Verify that fob is present and turn ignition
key to IGNITION before removing main fuse or disconnecting
battery.
2.
See
. Using a swivel socket (2), remove nut
that secures the negative (-) battery cable (1) connector
to ground stud (4) on crankcase boss behind starter motor
assembly (3). Remove cable connector from stud.
3.
See
. Pull end of negative (-) cable (2) forward
gently to free it from cable holder (1).
4.
See
. Press main fuse holder (1) toward the
rear of the motorcycle until it pops off its mounting pin on
battery strap (4). Remove main fuse holder from battery
strap.
5.
Press data link connector (6) toward the rear of the
motorcycle until it pops off its mounting pin on battery
strap. Remove the connector from battery strap.
6.
Remove battery strap screw (5). Unhook battery strap
from battery tray mount on top of battery and remove strap.
7.
Lift up protective rubber boot covering battery positive (+)
terminal (3). Remove screw from battery positive (+) ter-
minal and remove positive (+) battery cable.
8.
Disconnect positive (+) battery cable from cable holder
(2).
9.
Slide the battery (with attached negative cable) out the
left side until the negative battery cable is accessible.
10. Disconnect the negative battery cable at the battery (-)
terminal. Leave the cable on the vehicle.
11. Remove battery from battery tray. Note routing of negative
(-) battery cable around frame downtube.
12. If battery is to be stored out of the motorcycle, close left
side cover.
1
2
3
4
sm06658
1. Negative (-) battery cable
2. Swivel socket
3. Starter motor assembly
4. Ground stud
Figure 1-69. Negative (-) Battery Connection
1
2
sm06659
1. Cable holder
2. Negative battery cable
Figure 1-70. Negative (-) Battery Cable Holder
1-60 2013 Sportster Service: Maintenance
3
4
1
5
6
2
sm06657
1. Main fuse and holder
2. Positive (+) battery cable holder
3. Positive (+) battery terminal (under protective
rubber boot)
4. Battery strap
5. Screw
6. Data link connector
Figure 1-71. Main Fuse and Battery Location: All Models
CLEANING AND INSPECTION
NOTE
Battery top must be clean and dry. Dirt and electrolyte on top
of the battery causes battery to self-discharge.
1.
Clean battery top with a solution of baking soda (sodium
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water).
2.
When the solution stops bubbling, rinse off the battery with
clean water.
3.
Clean cable connectors and battery terminals using a wire
brush or sandpaper. Remove any oxidation.
4.
Inspect the battery screws, and cables for breakage, loose
connections and corrosion.
5.
Check the battery terminals for melting or damage caused
by over-tightening.
6.
Inspect the battery for discoloration, raised top or a warped
or distorted case. This might indicate that the battery has
been frozen, overheated or overcharged.
7.
Inspect the battery case for cracks or leaks.
VOLTMETER TEST
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)
Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)
Voltmeter Test
The voltmeter test provides a general indicator of battery con-
dition. Check the voltage of the battery to verify that it is fully
charged.
1.
If the open circuit (disconnected) voltage reading is below
12.6 V:
a.
Charge the battery.
b.
Check the voltage after the battery has set for at least
one hour.
2.
If the voltage reading is 12.7 V or above:
a.
Perform a battery diagnostic test. See the electrical
diagnostic manual for the load test procedure.
b.
Refer to
Table 1-22. Voltmeter Test For Battery Charge Conditions
STATE OF CHARGE
VOLTAGE (OCV)
100%
12.7 V
75%
12.6 V
50%
12.3 V
25%
12.0 V
0%
11.8 V
CHARGING BATTERY
Safety Precautions
An automatic, constant monitoring battery charger/tender with
a charging rate of 5 amps or less at less than 14.6 volts is
recommended. The use of constant current chargers (including
trickle chargers) to charge sealed AGM batteries is not
recommended.
Any overcharge will cause dry-out and premature battery
failure. Always review charger instructions before charging a
battery. In addition to the manufacturer's instructions, follow
these general safety precautions:
•
Always wear eye, face and hand protection.
•
Always charge batteries in a well-ventilated area.
•
Turn the charger off before connecting or disconnecting
the leads to the battery to avoid dangerous sparks.
•
Never try to charge a visibly damaged or frozen battery.
•
Connect the charger leads to the battery. Red positive
lead to the positive terminal. Black negative lead to the
negative terminal. If the battery is still in the vehicle, con-
2013 Sportster Service: Maintenance 1-61
nect the negative lead to the chassis ground. Verify that
the ignition and all electrical accessories are turned off.
•
Verify that charger leads to battery are not separated,
frayed or loose.
•
If the battery temperature exceeds 110 °F (43 °C) during
charging, discontinue charger and allow the battery to
cool.
Using a Battery Charger
Charge the battery if:
•
Vehicle lights appear dim.
•
Electric starter sounds weak.
•
Battery has not been used for an extended period of time.
Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)
If battery releases an excessive amount of gas during
charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or
damage. (00413b)
1.
Check charge state with voltmeter test. If battery voltage
is less than 12.7 volts, see the next step.
NOTES
•
Most constant monitoring battery chargers are completely
automatic. They can be left connected to both AC power
and to the battery that is being charged. When leaving this
type of charger connected for extended periods of time,
periodically check the battery to see if it is unusually warm.
This is an indication that the battery may have a weak cell
or internal short. Read the manufacturer's instructions for
the charger.
•
Do not use battery chargers that produce excessively high
voltage designed for flooded batteries or excessively high
current designed for much larger batteries. Charging
should be limited to 5 amps maximum at no more than
14.6 volts.
Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)
Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged. (00214a)
2.
Connect red battery charger lead to the positive terminal
and black battery charger lead to the negative terminal of
the battery.
NOTE
If the battery is still in the vehicle, connect the negative lead
to the chassis ground. Be sure that the ignition and all electrical
accessories are turned off.
3.
Step away from the battery and turn on the charger.
Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)
4.
After the battery is fully charged, turn the charger OFF.
Disconnect the black battery charger lead to the negative
terminal of the battery.
5.
Disconnect the red battery charger lead to the positive
terminal of the battery.
6.
Mark the charging date on the battery.
7.
Perform a battery diagnostic test to determine the condition
of the battery. See the electrical diagnostic manual.
8.
If charging a battery because voltmeter test reading was
below 12.6 V, perform voltmeter test. See the electrical
diagnostic manual.
BATTERY INSTALLATION AND
CONNECTION
TORQUE VALUE
FASTENER
6.8-7.9 Nm
60-70
in-lbs
Battery negative terminal
screw
4.1-6.8 Nm
36-60
in-lbs
Battery strap screw
6.8-7.9 Nm
60-70
in-lbs
Battery positive terminal screw
6.2-8.5 Nm
55-75
in-lbs
Battery cable connector nut
Connect the cables to the correct battery terminals. Failure
to do so could result in damage to the motorcycle electrical
system. (00215a)
1.
Open left side cover.
2.
Apply a light coat of petroleum jelly or corrosion retardant
material to the negative (-) battery terminal.
3.
Slide fully charged battery into battery tray.
4.
Insert screw through negative battery cable and into neg-
ative battery terminal. Thread screw into terminal. Tighten
screw to 60-70
in-lbs
(6.8-7.9 Nm).
5.
Verify that the negative (-) battery cable is disconnected
from the ground stud on crankcase.
6.
Hook top of battery strap (4) to battery tray mount on top
of battery. Install strap screw (5). Tighten to 36-60
in-lbs
(4.1-6.8 Nm).
1-62 2013 Sportster Service: Maintenance
7.
Route main positive battery cable through holders on
electrical bracket.
8.
Hook main fuse holder (1) to top pin on battery strap and
slide forward until it snaps into place.
9.
Hook data link connector (6) to bottom pin on battery strap
and slide forward until it snaps into place.
10. See
. Press negative (-) battery cable (2) into
cable holder (1).
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)
11. See
. With negative battery cable disconnected,
insert positive terminal screw through main fuse cable
then main positive battery cable. Install screw into positive
battery terminal (3). Tighten to 60-70
in-lbs
(6.8-7.9 Nm).
12. Apply a light coat of petroleum jelly or corrosion retardant
material to the positive (+) battery terminal. Place pro-
tective rubber boot over terminal.
13. See
. Place negative (-) battery cable connector
onto ground stud (4) on crankcase boss behind starter
motor assembly (3). Thread nut onto stud.
14. See
or
. Press negative (-) battery
cable connector (1) against cable stop (2) on crankcase
and tighten nut (3) to 55-75
in-lbs
(6.2-8.5 Nm).
15. Close left side cover.
2
3
1
sm03277a
1. Negative battery cable connector
2. Cable stop
3. Nut
Figure 1-72. Attaching Negative (-) Battery Cable to Ground
Stud Crankcase: XL Models
1
2
3
sm05267a
1. Negative battery cable connector
2. Cable stop
3. Nut
Figure 1-73. Attaching Negative (-) Battery Cable to Ground
Stud Crankcase: XR 1200X
STORAGE
TOOL NAME
PART NUMBER
GLOBAL BATTERY CHARGER
99863-01A
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)
If the motorcycle is stored with the security system armed,
connect
an
automatic,
constant
monitoring
battery
charger/tender to maintain battery charge. Refer to the Harley-
Davidson Parts and Accessories catalog.
If the motorcycle is stored with the battery installed, without a
GLOBAL BATTERY CHARGER, and with the security system
not
armed, remove main fuse.
If the motorcycle will not be operated for several weeks, such
as during the winter season, remove the battery from the
motorcycle and fully charge.
See
. A battery that is removed from the vehicle is
affected by self-discharge. A battery that is stored in the vehicle
is affected by self-discharge and, more significantly, by parasitic
loads. A parasitic load is caused by things like diode leakage
or maintaining computer memory with the vehicle turned off.
Batteries self-discharge at a faster rate at higher ambient
temperatures. To reduce the self-discharge rate, store battery
in a cool, dry place.
Charge the battery every two weeks if stored in the vehicle.
Charge the battery once per month if stored out of the vehicle.
NOTE
Use the GLOBAL BATTERY CHARGER (Part No. 99863-01A)
to maintain battery charge for extended periods of time without
risk of overcharging or boiling.
2013 Sportster Service: Maintenance 1-63
3
6
9
12
15
50 %
75 %
100 %
0
2
4
3
1
om00036
1. Capacity
2. Months of non-use
3. Measured at 105 °F (40 °C)
4. Measured at 77 °F (25 °C)
Figure 1-74. Effective Rate of Temperature on Battery
Self-discharging Rate
1-64 2013 Sportster Service: Maintenance
1.23
EXHAUST SYSTEM
EXHAUST SYSTEM LEAK CHECK
1.
Check entire exhaust system for loose or missing
fasteners, damaged pipe clamps or brackets, and obvious
signs of leakage (carbon tracks at pipe joints, etc.).
2.
Check for loose or damaged heat shields. Repair or
replace as necessary.
3.
Check for exhaust leaks:
a.
Start engine.
b.
Cover muffler end with a clean dry shop towel.
c.
Listen for exhaust leakage.
d.
Remove shop towel.
4.
Correct any leaks detected. See
or
.
2013 Sportster Service: Maintenance 1-65
1.24
WHEEL ALIGNMENT
WHEEL ALIGNMENT
TOOL NAME
PART NUMBER
AXLE ALIGNMENT PLUGS
HD-48856-A
TORQUE VALUE
FASTENER
129-142 Nm
95-105 ft-lbs
Axle, rear, nut
Checking Wheel Alignment
Check vehicle alignment according to following proced-
ures. Incorrect alignment can adversely affect stability and
handling, which could result in death or serious injury.
(00287a)
NOTE
Some models may require muffler removal.
1.
See
. Insert alignment plugs (1, 2) from the
AXLE ALIGNMENT PLUGS (Part No. HD-48856-A) into
right and left ends of rear axle. Turn handle until plug is
firmly held in the axle.
2.
XL Models:
See
. Fabricate an alignment tool
using a piece of 1/8 in (3.175 mm) diameter aluminum
welding rod 21.5 in (546 mm) long:
a.
Grind one end down to a blunt point.
b.
Use pliers to bend rod at a 90 degree angle, 2.25 in
(57 mm) from the blunt point.
c.
Place a snug-fitting rubber grommet (2) on rod to act
as a slide measurement indicator.
3.
XR 1200X:
See
. Fabricate an alignment tool
using a piece of 1/8 in (3.175 mm) diameter aluminum
welding rod 22.375 in (568 mm) long:
a.
Grind one end down to a blunt point.
b.
Use pliers to bend rod as shown.
c.
Place a snug-fitting rubber grommet (2) on rod to act
as a slide measurement indicator.
4.
Gauge distance between rear fork pivot bolt and rear axle
alignment plug center:
a.
See
. Insert blunt point of alignment tool
in rear fork pivot bolt dimple (2) on right side of rear
fork (3).
b.
Slide rubber grommet along tool shaft until it aligns
with hole in center of alignment plug (5).
c.
Without moving grommet, position alignment tool on
left side of rear fork.
5.
Verify measurements match on both sides of axle. Adjust
if necessary.
1
2
sm07441a
1. RH alignment plug
2. LH alignment plug
Figure 1-75. Axle Alignment Plugs
1
2
3
4
sm05426
1. Blunt point
2. Rubber grommet
3. 2.25 in (57 mm)
4. 19.25 in (489 mm)
Figure 1-76. Wheel Alignment Tool: XL Models
1-66 2013 Sportster Service: Maintenance
1
6
2
5
3
4
sm05427
1. Blunt point
2. Rubber grommet
3. 5/8 in (16 mm)
4. 15-1/4 in (387 mm)
5. 6-1/2 in (165 mm)
6. 3-7/8 in (98 mm)
Figure 1-77. Wheel Alignment Tool: XR 1200X
1
3
5
4
2
sm01615a
1. Wheel alignment tool
2. Rear fork pivot bolt dimple
3. Rear fork
4. Rubber grommet
5. Axle alignment plug
Figure 1-78. Checking Wheel Alignment Using Wheel
Alignment Tool: XL Models
Adjusting Wheel Alignment
1.
Remove and discard E-clip.
2.
Loosen rear axle nut.
3.
On side of rear fork that has longer distance from pivot
bolt to axle center, turn nut on axle adjuster counterclock-
wise to shorten distance. Adjust axle until left and right
side alignment measurements are equal.
NOTES
•
Keep axle adjuster mechanisms firmly seated (under ten-
sion) on each side of rear fork during wheel alignment
procedures above. Do so by applying moderate upward
force on lower span of drive belt. This tensions drive belt,
which holds rear axle forward against both adjuster
mechanisms.
•
Do not tighten rear axle nut or install new E-clip until after
checking drive belt tension.
4.
Verify drive belt deflection after aligning rear wheel. Adjust
if required. See
1.12 DRIVE BELT AND SPROCKETS,
NOTE
If rear axle has been moved, verify slack in rear brake line
between clamp and rear caliper. If necessary, reposition brake
line. See
1.12 DRIVE BELT AND SPROCKETS, Drive Belt
Do not exceed specified torque when tightening axle nut.
Exceeding torque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious
injury. (00408e)
5.
Tighten axle nut to 95-105 ft-lbs (129-142 Nm) and install
new
E-clip.
6.
Install muffler if removed.
2013 Sportster Service: Maintenance 1-67
1.25
SUSPENSION ADJUSTMENTS
FRONT FORK: XR 1200X
Adjust both forks equally. Improper fork adjustment can
lead to loss of control, which could result in death or ser-
ious injury. (00124c)
Compression and rebound adjusting valves may be dam-
aged if too much force is used at either end of the adjust-
ment range. (00237a)
Spring Preload
1.
See
. With a hex key, turn the preload adjuster
counterclockwise until it stops. This is the minimum preload
setting.
2.
Calculate the total load and turn the adjuster clockwise to
specification. Refer to
Rebound Damping
1.
See
. Turn the rebound damping adjuster (1)
clockwise H (hard) until it stops. This is the maximum
rebound setting.
2.
Turn adjuster counterclockwise S (soft) to specification.
Refer to
.
Compression Damping
1.
See
. Turn the compression damping adjuster
(2) clockwise H (hard) until it stops. This is the maximum
compression setting.
2.
Turn the adjuster counterclockwise S (soft) to specification.
Refer to
.
om01386
Figure 1-79. Spring Preload Adjuster: XR 1200X
Table 1-23. Recommended Spring Preload: XR 1200X
TURNS**
FROM
MINIMUM
LOAD*
0-4
Less than 165 lb (75.0 kg)
4-6
165-195 lb (75.0-89.0 kg)
6-8
195-225 lb (89.0-102.0 kg)
8-10
225-255 lb (102.0-116.0 kg)
More than 10
255 lb (116.0 kg) to maximum added weight
allowed. Refer to
.
*Add the weight of the rider, passenger, riding gear,
accessories, and cargo.
**Turns are clockwise turns in from minimum.
•
To increase preload, turn the adjuster clockwise.
•
To decrease preload, turn the adjuster counterclockwise.
1
2
om01385
1. Rebound damping adjuster
2. Compression damping adjuster
Figure 1-80. Fork Rebound and Compression Damping
Adjusters: XR 1200X
Table 1-24. Recommended Fork Rebound and
Compression Damping: XR 1200X
TURNS FROM MAX**
DAMPING*
3
Rebound (REB)
5
Compression (COM)
*Turns are counterclockwise out from maximum.
•
To increase damping, turn adjuster clockwise (H).
•
To decrease damping, turn adjuster counterclockwise
(S).
1-68 2013 Sportster Service: Maintenance
SHOCK ABSORBER PRELOAD: ALL
MODELS
TOOL NAME
PART NUMBER
SHOCK ADJUSTMENT SPANNER
94448-82B
Adjust both shock absorbers equally. Improper adjustment
can adversely affect stability and handling, which could
result in death or serious injury. (00036b)
Do not turn the shock absorber adjustment collar clock-
wise beyond adjustment setting 5. Doing so may result in
equipment damage. (00166b)
NOTES
•
Five position shocks: See
. Do not turn the
preload cam past position five (5) to position one (1) or
from position one (1) to position five (5).
•
Three position shocks: Do not turn the preload cam past
position three to position one or from position one (1) to
position three.
XL Models:
See
. Using SHOCK ADJUSTMENT
SPANNER (Part No. 94448-82B), turn the adjustment cam to
specification.
•
Five position shocks:
Refer to
•
Three position shocks:
Refer to
XR 1200X:
See
. Use the spanner wrench with
extension handle from the tool kit to turn the adjustment cam
to specification. Refer to
om00396a
Figure 1-81. Shock Absorber Preload Adjustment: XL
Models
om01381b
Figure 1-82. Shock Absorber Preload Adjustment: XR
1200X
2
1
5
3
4
pd00442
Figure 1-83. Shock Preload Cam Positions (typical)
XL 883L/N, XL1200X/V and certain XL1200CP models are
configured for solo operation. If you choose to add a passenger
and/or cargo to the vehicle, the ride quality may be comprom-
ised. See a Harley-Davidson dealer for two-up seats, passenger
pegs and suspension options.
Table 1-25. Recommended Shock Preload: Five Position
POSITION**
LOAD*
1
Less than 165 lb (75.0 kg)
2
165-195 lb (75.0-89.0 kg)
3
195-225 lb (89.0-102.0 kg)
4
225-255 lb (102.0-116.0 kg)
5
255 lb (116.0 kg) to maximum added
weight allowed. Refer to
and
.
* Add the weight of the rider, passenger, riding gear,
accessories, and cargo.
** See
2013 Sportster Service: Maintenance 1-69
Table 1-26. Recommended Shock Preload: Three Position
POSITION
LOAD*
1
Less than 165 lb (75.0 kg)
2
165-225 lb (75.0-102.0 kg)
3
225 lb (102.0 kg) to maximum added
weight allowed. Refer to
and
.
* Add the weight of the rider, passenger, riding gear,
accessories, and cargo.
Table 1-27. Maximum Added Weight Allowed: Sportster
Models
MAX LOAD
MODEL
kg
lb
198.2
437
XL 883L
197.3
435
XL 883N
193.7
427
XL 883R
189.6
418
XL 1200C/C ANV/CP
193.7
427
XL 1200CA
193.7
427
XL 1200CB
196.4
433
XL 1200X
201.8
445
XL 1200V
193.7
427
XR 1200X
SHOCK ABSORBER REBOUND AND
COMPRESSION: XR 1200X
Adjust both shock absorbers equally. Improper adjustment
can adversely affect stability and handling, which could
result in death or serious injury. (00036b)
Compression and rebound adjusting valves may be dam-
aged if too much force is used at either end of the adjust-
ment range. (00237a)
Shock Absorber Rebound Damping
Adjustment
1.
See
. Turn the rebound adjuster in the direction
of the embossed H (hard) until it stops. This is the max-
imum rebound damping setting.
2.
Turn the rebound adjuster toward the embossed S (soft)
the recommended number of clicks. Refer to
Shock Absorber Compression Damping
Adjustment
1.
See
. Using fingers, turn the compression
adjuster clockwise H (hard) until it stops. This is the max-
imum compression damping setting.
2.
Turn the compression adjuster counterclockwise (H to S)
(hard to soft) the recommended number of clicks. Refer
to
om01382
Figure 1-84. Rebound Damping Adjuster: XR 1200X
sm06884
Figure 1-85. Compresson Damping Adjuster: XR 1200X
Table 1-28. Recommended Rear Shock Rebound and
Compression Damping: XR 1200X
CLICKS FROM MAX
(H to S)
DAMPING
5
Rebound (REB)
7
Compression (COMP)
SUSPENSION TUNING: XR 1200X
After the suspension has been set to the recommend settings
and the tires have been inflated to recommended pressures,
ride the motorcycle and adjust the suspension damping as
required. Refer to
1-70 2013 Sportster Service: Maintenance
Table 1-29. Suspension Damping Adjustment Guidelines: XR 1200X
SUGGESTED REMEDY
MOTORCYCLE BEHAVIOR
Increase rebound damping.
Soft or unsettled feeling around corners or after bumps
Increase rebound damping.
Leaping feeling or topping after large bumps
Decrease rebound damping.
Harsh/sharp feedback over bumps
Decrease rebound damping.
Feels like motorcycle drops down over chatter bumps
Increase compression damping.
Excessive bottoming through potholes
Increase compression damping (forks).
Excessive dive when applying front brake
Decrease compression damping.
Hard feeling or inadequate absorption over bumps
Decrease compression damping.
Feels excessively stiff or busy around corners
2013 Sportster Service: Maintenance 1-71
1.26
HEADLAMP ALIGNMENT
HEADLAMP ALIGNMENT
The automatic-on headlamp feature provides increased
visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)
NOTE
Adjust the headlamps of motorcycles with multiple beam
headlamps to converge into one pattern.
1.
Check the tire pressure.
2.
Adjust the rear shocks for the rider and intended load.
3.
Fill fuel tank or add an equal amount of ballast.
NOTE
Choose a wall in minimum light.
4.
See
. Park the motorcycle in a line (1) perpen-
dicular to the wall.
5.
Position motorcycle so that front axle is 25 ft (7.6 m) from
wall.
6.
Draw a vertical line (2) on the wall.
7.
With the motorcycle loaded, point the front wheel straight
forward at wall. Measure the distance (4) from the floor to
the center of the high beam bulb.
8.
Draw a horizontal line (5) through the vertical line on the
wall. Place line 2.1 in (53.3 mm) lower than the measured
bulb centerline.
NOTE
The headlamp is aligned when the light beam hot spot is
centered over the intersection of the lines.
9.
Verify headlamp alignment. Adjust as necessary.
¨
2
1
5
3
4
om00835c
1. Perpendicular line
2. Vertical line
3. 25 ft (7.6 m)
4. High beam bulb centerline
5. Horizontal line 2.1 in (53.3 mm) lower than bulb
centerline
Figure 1-86. Headlamp Alignment: Sportster Models
HEADLAMP: ADJUSTMENT
TORQUE VALUE
FASTENER
40.7-47.5 Nm
30-35 ft-lbs
Headlamp horizontal adjust-
ment: XL 1200X/C/C
ANV/CP/CA/CB/V
40.7-47.5 Nm
30-35 ft-lbs
Headlamp vertical adjustment:
XL 1200X/C/C
ANV/CP/CA/CB/V
14-27 Nm
120-240
in-lbs
Headlamp clamp nut: XL
883L/N/R, XR 1200X
Adjustment: XL 1200X/C/C ANV/CP/CA/CB/V
1.
Set horizontal adjustment:
a.
See
. Loosen the horizontal adjustment
screw (3).
b.
Turn the headlamp right or left as necessary to direct
the light beam straight ahead.
c.
Tighten the horizontal adjustment screw to 30-35 ft-
lbs (40.7-47.5 Nm).
2.
Set vertical adjustment:
a.
Loosen the locknut (1) for the vertical adjustment bolt.
b.
Tilt headlamp up or down to properly aim it at the
horizontal line on the wall.
c.
Tighten headlamp locknut to 30-35 ft-lbs (40.7-47.5
Nm).
1-72 2013 Sportster Service: Maintenance
2
3
1
sm06940
1. Locknut
2. Vertical adjustment bolt
3. Horizontal adjustment screw
Figure 1-87. Headlamp Adjustment: XL 1200X/C/C
ANV/CP/CA/CB/V
Adjustment: XL 883R/L/N, XR 1200X
1.
See
. Remove snap plug (1) on top of head-
lamp bracket (2).
2.
Loosen headlamp clamp nut (3).
3.
Tilt headlamp up or down to properly aim it in relation to
the horizontal line and, at the same time, turn it right or
left to direct light beam straight ahead.
4.
Tighten headlamp clamp nut to 120-240
in-lbs
(14-27 Nm)
after lamp is properly positioned.
5.
Install snap plug in headlamp bracket.
3
1
2
om01439
1. Snap plug
2. Headlamp bracket
3. Clamp nut
Figure 1-88. Headlamp Adjustment: XL 883R/L/N, XR 1200X
(XR 1200X shown)
2013 Sportster Service: Maintenance 1-73
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