Harley Davidson 2013 Sportster Models. Service Manual — page 7

sm05586

1. Screw (2)
2. Voltage regulator
3. Stator wiring
4. Cable strap

Figure 6-94. Stator Wire Routing: XR 1200X

INSTALLATION: XR 1200X

TORQUE VALUE

FASTENER

4.1-6.8 Nm

36-60

in-lbs

Voltage regulator mounting
screw

See

Figure 6-95

. Position voltage regulator close to

mounting bracket (1). Orient regulator so cooling fins face
forward and wiring harnesses exit regulator body toward
right side of vehicle.

Thread DC output wires below mounting bracket. Route
DC output connector (2) toward left side of vehicle.

Route stator wires (4) down along between right frame
downtube and body of voltage regulator. Route stator
harness connector [46A] toward right side of vehicle.

NOTE

Verify that the wires do not get pinched between bracket and
regulator.

Secure voltage regulator on mounting bracket with
mounting screws. Tighten to 36-60

in-lbs

(4.1-6.8 Nm).

See

Figure 6-96

. Connect stator connector (1) and fold

external latch over and lock in place. Secure stator con-
nector to bracket with barbed cable strap (3).

Secure stator wires to right frame down tube with cable
strap (2).

See

Figure 6-97

. Connect voltage regulator DC output

connector. Fold external latch over and lock in place.

Secure DC output connector (2) along with oil pressure
switch, neutral switch harness (3) to voltage regulator
bracket with cable strap (1).

Install main fuse.

10. Test charging system. See the electrical diagnostic

manual.

sm05588

1. Voltage regulator mounting bracket
2. DC output connector
3. DC output wires
4. Stator wires

Figure 6-95. Voltage Regulator Wire Routing: XR 1200X

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6-62 2013 Sportster Service: Electrical

sm05589

1. Stator connector
2. Cable strap
3. Barbed cable strap

Figure 6-96. Stator Connector: XR 1200X

sm05585

1. Cable strap
2. DC output conector
3. Oil pressure switch, neutral switch harness
4. Oil filter

Figure 6-97. DC Output Connector: XR 1200X

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2013 Sportster Service: Electrical 6-63

sm06842

1. Hex lockplate and spring
2. Adjusting screw

Figure 1-26. Clutch Adjustment Screw

Lever Free Play

Turn the adjuster away from the jamnut until there is no
slack in the cable at the clutch lever.

See

Figure 1-27

. Pull the clutch cable ferrule (2) away

from the clutch lever bracket (3) and measure the free
play (4).

Adjust to specification. Refer to

Table 1-11

Tighten the jamnut to 120

in-lbs

(13.6 Nm).

Pull the rubber boot over the cable adjuster.

XL Models:

Secure the cable in the cable retainers.

Install main fuse.

sm01439

1. Clutch cable
2. Cable ferrule
3. Clutch lever bracket
4. 1/16-1/8 in (1.6-3.2 mm) free play

Figure 1-27. Clutch Free Play Adjustment

Table 1-11. Clutch Lever Free Play Specifications

FREE PLAY

1.6-3.2

1/16-1/8

Measurement

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1-30 2013 Sportster Service: Maintenance

1.12

DRIVE BELT AND SPROCKETS

GENERAL

Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)

In the case of stone damage to belt, inspect the sprockets for
damage and replace as required. If replacing belt, always
replace both transmission and rear sprockets.

CLEANING

Keep dirt, grease, oil, and debris off the drive belt and
sprockets. Clean the belt with a rag slightly dampened with a
light cleaning agent.

INSPECTION

Sprockets

NOTE

Chrome chips or rear sprocket gouges large enough to be
harmful will leave a pattern on the belt face.

See

Figure 1-28

. Inspect each tooth (1) of rear sprocket

for:

Tooth damage.

Large chrome chips with sharp edges.

Gouges caused by hard objects.

Excessive loss of chrome plating (see next step).

To check if chrome plating has worn off, drag a scribe or
sharp knife point across the bottom of a groove (2)
(between two teeth) with medium pressure.

If scribe or knife point slides across groove without
digging in or leaving a visible mark, chrome plating
is still good.

If scribe or knife points digs in and leaves a visible
mark, it is cutting the bare aluminum. A knife point
will not penetrate the chrome plating.

Replace rear sprocket if major tooth damage or loss of
chrome exists.

sm03283

1. Tooth
2. Groove

Figure 1-28. Rear Sprocket

Idler Pulley: XR 1200X

See

Figure 1-29

. Inspect idler pulley for signs of uneven wear.

Excessive lateral side play of 0.035 in (0.9 mm) or roughness
indicates worn bearings. Replace idler pulley as an assembly.
See

5.6 DRIVE BELT

sm00093

Figure 1-29. Measuring Lateral Side Play on Idler Pulley

Drive Belt

NOTE

Belt teeth are coated with polyethylene lubricant. Coating will
wear off over time. This is not an indicator of belt wear.

See

Figure 1-30

. Inspect drive belt for:

•

Cuts or unusual wear patterns.

•

Outside edge bevelling (8). Some bevelling is common,
but it indicates that sprockets are misaligned.

•

Stone punctures (7) on outside ribbed surface. If
cracks/damage exists near edge of belt, replace belt
immediately. Damage to center of belt will require belt
replacement eventually. When cracks extend to the edge
of the belt, failure is imminent.

•

Inside (toothed portion) of belt for exposed tensile cords
(normally covered by nylon layer and polyethylene layer).

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2013 Sportster Service: Maintenance 1-31

This condition will result in belt failure and indicates worn
transmission sprocket teeth. Replace belt and transmission
sprocket.

•

Signs of puncture or cracking at the base of the belt teeth.
Replace belt if either condition exists.

•

If conditions 2, 3, 6 or 7 (on edge of belt) exist, replace
belt.

NOTE

Condition 1 may develop into 2 or 3 over time. Condition 1 is
not grounds for replacing the belt, but it should be watched
closely before condition 2 develops which will require belt
replacement.

Table 1-12. Drive Belt Wear Analysis

REQUIRED ACTION

CONDITION

NO.*

OK to run, but monitor condi-
tion.

Internal tooth cracks
(hairline)

Replace belt.

External tooth cracks

Replace belt.

Missing teeth

OK to run, but monitor condi-
tion.

Chipping
(not serious)

OK to run, but monitor condi-
tion.

Fuzzy edge cord

Replace belt and sprocket.

Hook wear

Replace belt if damage is on
the edge.

Stone damage

OK to run, but monitor condi-
tion.

Bevel wear
(outboard edge only)

Check idler bearings and
bracket attachment.

Excess edge wear

XR only

* See

Figure 1-30

sm06897a

Figure 1-30. Drive Belt Wear Patterns

DRIVE BELT DEFLECTION

TOOL NAME

PART NUMBER

BELT TENSION GAUGE

HD-35381A

TORQUE VALUE

FASTENER

129-142 Nm

95-105 ft-lbs

Axle, rear, nut

3.4-4.5 Nm

30-40

in-lbs

Brake hose clamp to rear fork
screw

Gauging Deflection

Check belt deflection at the loosest spot in the belt with the
transmission in neutral and the motorcycle at ambient temper-
ature.

With the motorcycle unladen and resting on its jiffy stand,
fit the BELT TENSION GAUGE (Part No. HD-35381A) on
the belt.

XL Models:

See

Figure 1-31

. Position the gauge half-

way between the transmission and rear wheel
sprockets.

XR 1200X:

See

Figure 1-32

. Fit the tension gauge

half-way (1) between the idler wheel and rear
sprocket.

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1-32 2013 Sportster Service: Maintenance

With the BELT TENSION GAUGE set to 0 lb (0 kg), note
the current belt position.

XL Models:

See

Figure 1-31

. View position through

window on drive belt guard.

XR 1200X:

See

Figure 1-32

. Check position (2) on

front of debris deflector.

Using the BELT TENSION GAUGE, apply 10 lb (4.5 kg)
of force to the bottom belt.

Count the number of gradations (3) between the original
belt position and after applying the force. Multiply this
number by 1/8 in (3.2 mm) to determine the deflection.

Compare the deflection to specifications. Refer to

Table 1-13

Adjust as necessary.

Be sure wheel and brake caliper are aligned. Riding with
a misaligned wheel or brake caliper can cause the brake
disc to bind and lead to loss of control, which could result
in death or serious injury. (00050a)

NOTE

When gauging deflection, check the rear brake caliper position
on rear brake disc. Disc should run true within brake caliper.

Table 1-13. Belt Deflection Specifications*

MODELS

14.3-15.9

9/16-5/8

XL 883R

6.4-7.9

1/4-5/16

Other XL models

6.4-9.5

1/4-3/8

XR 1200X

* Deflection measured at 10 lb (4.5 kg) tension.

spare

om01614

1. 10 lb (4.5 kg)
2. Deflection gauge
3. Graduations 1/8 in (3.2 mm)

Figure 1-31. Belt Deflection: XL Models

om01272c

1. 10 lb (4.5 kg)
2. Deflection gauge
3. Graduations 1/8 in (3.2 mm)

Figure 1-32. Belt Deflection: XR 1200X

Adjustment

NOTE

Rear brake line is clamped tightly to rear fork to avoid chafing
of brake line in clamp. A small amount of slack must be main-
tained in rear brake line between clamp and rear caliper when
rear wheel is adjusted.

XL Models:

See

Figure 1-33

. Remove screw (4) from

clamp (3) on rear brake line (2).

See

Figure 1-34

. Remove and discard E-clip (1) and

loosen rear axle nut (4).

NOTE

Turn both adjuster nuts the same number of turns in order to
maintain approximate alignment of rear wheel.

Turn axle adjuster nuts (2) on each side of rear fork
clockwise to decrease belt deflection (increase tension),
or counterclockwise to increase belt deflection (decrease
tension).

Check rear wheel alignment. See

1.24 WHEEL ALIGN-

MENT, Wheel Alignment

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)

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2013 Sportster Service: Maintenance 1-33

sm01666a

1. Motor sprocket
2. Rotor
3. Screw (4)
4. Stator
5. Stator wiring harness
6. Connector [46B]
7. Bolt (8)
8. Stator harness retainer
9. Screw (2)
10. Stator harness grommet

Figure 6-100. Alternator Components

CLEANING AND INSPECTION

Remove debris from rotor magnets. Clean rotor by wiping
thoroughly with a clean cloth.

Check rotor for:

Loose or cracked magnets.

Stator bolt contact with rotor.

Spline damage to rotor center mounting bolt hole.

Clean stator, stator leads and grommet thoroughly with a
clean cloth.

Check stator for:

Contact with rotor.

Damaged or cracked insulation.

Electrical failures. See the electrical diagnostic
manual.

NOTE

Replace parts as necessary.

ASSEMBLY AND INSTALLATION

TORQUE VALUE

FASTENER

3.4-4.5 Nm

30-40

in-lbs

Alternator stator mounting
screw

6.3 Nm

in-lbs

Stator harness retainer screw

13.6-15.8 Nm

120-140

in-lbs

Alternator rotor to sprocket
screw

Stator

See

Figure 6-100

. Feed stator wiring harness (5) with

attached grommet (10) into open grommet hole in left
crankcase half.

Apply a light coating of clean engine oil to grommet. Press
grommet into hole in left crankcase half.

Position stator (4) on left crankcase half. Secure stator
using

new

TORX screws. Use TORX driver to tighten

screws to 30-40

in-lbs

(3.4-4.5 Nm).

Position stator harness retainer (8) over harness and onto
engine crankcase with mounting holes facing aft. Secure
with two screws (9). Verify that the harness is not pinched.
Tighten to 56

in-lbs

(6.3 Nm) (maximum). Do not exceed

torque specification.

Route stator wiring harness across top of crankcase halves
to right side of engine. Route stator harness downward
through opening between right crankcase half and gear-
case cover.

Route stator harness forward and then upward along
inboard side of right frame downtube.

Connect stator harness to voltage regulator harness at
connector [46] and lock external latch in place. See

6.23 VOLTAGE REGULATOR

for procedure.

Secure stator harness and neutral switch with cable straps
as noted from stator removal.

Rotor: XL Models

NOTE

XR 1200X rotor assembly is not serviceable. If damaged,
replace the entire engine sprocket/rotor assembly.

See

Figure 6-101

. Position rotor (1) on sprocket (2). Align

holes in sprocket with holes in rotor.

Apply a drop of LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to each mounting
bolt. Insert mounting bolts through rotor. Start bolts into
tapped holes in sprocket.

Position a section of pipe (3) with an inside diameter larger
than the sprocket mounting hub over center of rotor.

Press rotor onto sprocket. Tighten to 120-140

in-lbs

(13.6-

15.8 Nm).

Final Assembly

Install clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See

5.4 PRIMARY

DRIVE AND CLUTCH: XL MODELS

5.5 PRIMARY

DRIVE AND CLUTCH: XR 1200X

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