Harley Davidson 2013 Sportster Models. Service Manual — page 25
NOTE
Do not install IAC mounting screw on throttle wheel side of
induction module until cable bracket is installed. Install other
IAC mounting screw but do not tighten at this time.
4.
See
. Install cable bracket (3) onto induction
module (4):
a.
Obtain
new
screws (1, 2) or apply LOCTITE 243
MEDIUM
STRENGTH
THREADLOCKER
AND
SEALANT (blue) to existing screws.
b.
Install both screws finger-tight.
c.
Tighten both IAC mounting screws to 60
in-lbs
(6.8
Nm). Tighten side screw (1) to 60
in-lbs
(6.8 Nm).
5.
Install fuel injectors, fuel rail and fuel hose. See
INSTALLATION
TORQUE VALUE
FASTENER
10.2-13.6 Nm
90-120
in-lbs
Induction module mounting
bracket screw: XL models
10.9-13.6 Nm
96-120
in-lbs
Intake manifold mounting
screw: XL models
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank fasteners: XL
Models
1.
See
. Make sure two mounting screws (2) are
screwed into heads two or three turns.
2.
See
. Install mounting flanges (1) on intake
manifold (5) with counterbore (2) facing away from mani-
fold and open slotted ends of flanges facing away from
induction module (6).
3.
Place a
new
seal (3) into each mounting flange with the
beveled edge (4) facing the mounting flange counterbore.
NOTE
When induction module is positioned on manifold mounting
screws, Verify the flanges are correctly installed on the mani-
fold. Verify the rubber seals are in place.
4.
Place induction module assembly in position between
engine heads. Slide open slotted ends of mounting flanges
under heads of two mounting screws on left side of engine.
5.
See
. Holding induction module/intake manifold
assembly in place, install two mounting screws (3) into
remaining mounting flange holes. Tighten all four screws
finger-tight.
6.
See
. Install mounting bracket (1) and screw
(2). Tighten screw finger-tight.
7.
Temporarily install two breather screws through mounting
bracket. Thread breather screws into cylinder heads finger-
tight. This will properly line up induction module assembly.
8.
Tighten mounting bracket screws to 90-120
in-lbs
(10.2-
13.6 Nm).
9.
Tighten all four intake manifold mounting screws to 96-
120
in-lbs
(10.9-13.6 Nm).
10. See
. Install idle cable barrel (4) into throttle
wheel (6). Slide idle cable (3) through slot (5) and wind
around groove in throttle wheel.
11. Pull cable through slot in cable guide (7). Slide spring (2)
and end of idle cable housing (1) down into cable guide.
12. See
. Install throttle cable barrel (6) into throttle
wheel (7). Slide throttle cable through slot (8) and wind
around groove in throttle wheel.
13. Pull cable through slot (4) in cable guide (3). Slide end of
throttle cable housing (1) down into cable guide.
14. Adjust throttle and idle cables. See
1
4
1
5
2
6
2
3
sm01590
1. Mounting flange (2)
2. Counterbore
3. Seal (2)
4. Beveled edge
5. Intake manifold
6. Induction module
Figure 4-40. Installing Mounting Flange and Seal
2013 Sportster Service: Fuel System 4-27
15.
EVAP Controlled Models:
See
. Install purge
hose onto fitting (2) on induction module (1).
16. See
. Plug in the following connectors:
a.
Front fuel injector (1) connector [84],
b.
Rear fuel injector (2) connector [85],
c.
TMAP sensor (3) connector [80],
d.
IAC (4) connector [87],
e.
TPS (5) connector [88].
17. Remove prop from under rear of fuel tank. Lower rear of
fuel tank into position. Install fastener, washer and nut in
fuel tank rear mounting holes. Tighten to 15-20 ft-lbs (20.3-
27.1 Nm). Install protective caps on screw ends. See
18. Install air cleaner assembly. See
.
To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)
19. Connect fuel hose to fuel pump module. Fill fuel tank.
Carefully check for leaks around fuel pump module. See
20. Install main fuse.
21. Close left side cover.
22. Turn ignition switch to ON and OFF to reset IAC to park
position.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
23. Install seat.
1
2
sm06574
1. Induction module
2. Purge hose (to canister) fitting
Figure 4-41. Purge Hose Fitting: CA Models
2
4
1
3
5
sm06873a
1. Front fuel injector [84A]
2. Rear fuel injector [85A]
3. TMAP sensor [80A]
4. IAC [87A]
5. TPS [88A]
Figure 4-42. Induction Module Electrical Connectors
4-28 2013 Sportster Service: Fuel System
4.9
INDUCTION MODULE: XR 1200X
REMOVAL
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Remove main fuse.
3.
Remove fuel tank and air box. See
and
4.3 AIR CLEANER ASSEMBLY, XR 1200X
4.
See
. Remove screws (3), fastener (1) and
fastener (2).
5.
Pull cover away from induction module and disengage
cable retainer from back side of cover. Remove cover.
6.
Disengage throttle cables from induction module. See
2.28 THROTTLE CABLES: ALL MODELS
7.
See
. Unplug the following connectors:
a.
Front fuel injector (3) [84],
b.
Rear fuel injector (4) [85],
c.
TMAP sensor (5) [80],
d.
IAC (6) [87],
e.
TPS (7) [88].
8.
EVAP Controlled Models:
Remove purge hose from fitting
(8).
9.
See
. Disconnect oil line flare nuts (1) from
flare fittings (2) in cylinder heads. Remove flare fittings (2)
from cylinder heads.
10. Loosen but do not remove left side screws holding induc-
tion module to cylinder head.
11. Remove two screws (3) securing induction module to cyl-
inder heads on right side of vehicle.
12. Remove induction module from engine.
2
1
3
3
sm06774b
1. Fastener, wire form
2. Fastener, to induction module
3. Screws (2)
Figure 4-43. Induction Module Cover: XR 1200X
2013 Sportster Service: Fuel System 4-29
1
2
3
9
5
6
7
8
4
10
11
sm04954
1. Induction module
2. Throttle cable bracket
3. Front fuel injector [84A]
4. Rear fuel injector [85A]
5. TMAP sensor [80A]
6. IAC [87A]
7. TPS [88A]
8. Purge hose fitting (EVAP models only)
9. Fuel supply hose
10. Throttle wheel
11. Fuel rail (not visible)
Figure 4-44. Induction Module
1
1
2
3
3
2
sm05420a
1. Flare nuts
2. Flare fittings
3. Fastener
Figure 4-45. Remove Induction Module
DISASSEMBLY
TOOL NAME
PART NUMBER
HEAT GUN
HD-25070
1.
See
. Remove retainer (7). Remove fuel rail
(8) with hose (4) and injectors (10) from the induction
module.
2.
Remove hose (4) and injectors (10) from fuel rail.
3.
Remove cable bracket (12).
NOTE
Screws (16) MUST be heated to soften the thread sealant and
avoid breakage during removal. Use ONLY HEAT GUN (Part
No. HD-25070) to heat the screws. NEVER use an open flame.
4.
Remove IAC (3). See
.
5.
Remove TMAP (15), and TPS (1).
6.
Remove mounting flanges (14) and seals (13).
4-30 2013 Sportster Service: Fuel System
15
11
14
13
12
10
9
8
6
5
4
7
3
16
2
1
sm05421
1. TPS
2. O-ring
3. IAC
4. Fuel hose
5. Nylon washer (included with hose (4))
6. O-ring (included with hose (4))
7. Retainer
8. Fuel rail
9. O-ring (4) (included in hardware and O-ring kit)
10. Fuel injector (2)
11. Screw
12. Throttle cable bracket
13. Intake seal
14. Mounting flange
15. TMAP sensor
16. Screw, IAC (2)
Figure 4-46. Induction Module
ASSEMBLY
TORQUE VALUE
FASTENER
6.8 Nm
60
in-lbs
IAC mounting screw: XR
1200X
6.8 Nm
60
in-lbs
Throttle cable bracket screw:
XR 1200X
1.
See
. Install the following:
a.
TPS. See
b.
TMAP sensor. See
ABSOLUTE PRESSURE (TMAP) SENSOR
.
c.
IAC. See
.
NOTE
Do not install IAC mounting screw on throttle wheel side of
induction module until cable bracket is installed. Install other
IAC mounting screw but do not tighten at this time.
2.
Install cable bracket (12) onto induction module:
a.
Apply
LOCTITE
243
MEDIUM
STRENGTH
THREADLOCKER AND SEALANT (blue) to the
threads of screw (11).
b.
Install screw finger-tight.
c.
Tighten both IAC mounting screws to 60
in-lbs
(6.8
Nm).
d.
Tighten screw (11) to 60
in-lbs
(6.8 Nm).
3.
Install fuel injectors, fuel rail and fuel hose. See
INSTALLATION
TORQUE VALUE
FASTENER
10.3-13.6 Nm
90-120
in-lbs
Intake manifold mounting
screw: XR 1200X
29.8-35.3 Nm
22-26 ft-lbs
Cylinder head oil feed flare fit-
ting: XR 1200X
17.6-23.0 Nm
13-17 ft-lbs
Cylinder head oil feed line
flare nut: XR 1200X
27.1-32.5 Nm
20-24 ft-lbs
Induction module cover to cyl-
inder head sockethead bolts:
XR 1200X
10.2-13.6 Nm
90-120
in-lbs
Induction module cover to
induction module fastener: XR
1200X
10.2-13.6 Nm
90-120
in-lbs
Induction module cover to wire
form fastener: XR 1200X
1.
Install the two left side mounting screws two or three turns
into the heads.
2.
See
. Install mounting flanges (3) on induction
module with counterbore (1) facing toward the engine.
3.
Install
new
seals (4).
a.
Placed the beveled edge facing the mounting flange
counterbore.
b.
Rotate the flange to the slotted mounting hole is on
the same side as the IAC solenoid.
NOTES
•
Verify that the flanges are installed on the manifold.
•
Verify that the rubber seals are in place.
4.
See
. Place induction module assembly in
position between engine heads. Slide open slotted ends
of mounting flanges under heads of two mounting screws
on left side of engine.
5.
While holding induction module assembly in place, install
two mounting screws (3) into remaining mounting flange
holes. Tighten all four screws finger-tight.
6.
Tighten to 90-120
in-lbs
(10.3-13.6 Nm).
7.
Inspect O-rings on flare fittings (2). Replace as necessary.
8.
Install flare fittings in cylinder heads. Tighten to 22-26 ft-
lbs (29.8-35.3 Nm).
2013 Sportster Service: Fuel System 4-31
9.
Connect oil line flare nuts (1) to flare fittings (2). Tighten
to 13-17 ft-lbs (17.6-23.0 Nm).
10. Install throttle cables. See
.
11. Adjust throttle and idle cables. See
.
3
4
1
2
sm05423
1. Beveled counterbore
2. Beveled edge
3. Mounting flange
4. Tapered seal
Figure 4-47. Mounting Flange and Seal
12.
EVAP Controlled Models:
See
. Install purge
hose onto fitting (8) on induction module (1).
NOTE
XR 1200X: See
. The fuel injector harness leads
must NEVER be routed between the retaining bracket (3) and
the induction module body (4). Improper routing will result in
chafing of the insulation resulting in poor engine performance.
13. See
. Plug in the following connectors:
a.
Front fuel injector (3) [84],
b.
Rear fuel injector (4) [85],
c.
TMAP sensor (5) [80],
d.
IAC (6) [87],
e.
TPS (7) [88].
14. Secure TPS harness to cover with a
new
cable strap with
anchor.
15. Install induction module cover. Finger tighten the fasteners.
16. Tighten:
a.
Socket headbolts to 20-24 ft-lbs (27.1-32.5 Nm).
b.
Cover-to-induction module fastener to 90-120
in-lbs
(10.2-13.6 Nm).
c.
Cover-to-wire form fastener to 90-120
in-lbs
(10.2-
13.6 Nm).
17. Install air box. See
18. Install fuel tank. See
.
19. Fill fuel tank. Check for leaks around fuel pump module
and quick connector. See
20. Install main fuse.
21. Close left side cover.
22. Reset IAC to park.
a.
Turn ignition to ON.
b.
Turn ignition to OFF.
23. Start engine. Check for fuel leaks.
3
2
1
4
sm06875
1. Front fuel injector [84]
2. Rear fuel injector [85]
3. Retaining bracket
4. Induction module
Figure 4-48. Fuel Injectors and Retaining Bracket
4-32 2013 Sportster Service: Fuel System
4.10
IDLE AIR CONTROL (IAC)
GENERAL
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
XL Models:
See
XR 1200X:
See
The ECM uses the IAC to control engine idle speed. See the
electrical diagnostic manual.
sm06869a
Figure 4-49. IAC: XL Models
sm06870a
Figure 4-50. IAC: XR 1200X
REMOVAL: XL MODELS
TOOL NAME
PART NUMBER
HEAT GUN
HD-25070
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.
Remove air cleaner assembly. See
.
3.
See
. Unplug harness connector [87B] from
IAC connector [87A] (1).
NOTE
Heat screws (2) to soften the thread sealant and avoid
breakage during removal. Use ONLY HEAT GUN (Part No. HD-
25070) to heat the screws. NEVER use an open flame.
2013 Sportster Service: Fuel System 4-33
4.
Using a six-point socket (not a Torx wrench), remove two
screws (2) in the following order:
a.
Heat fastener nearest to throttle bracket for two
minutes using HEAT GUN (Part No. HD-25070).
Remove screw.
b.
Heat remaining screw for one minute. Remove screw.
5.
See
. Grasp IAC and rotate clockwise until IAC
mounting tab (1) clears throttle cable bracket (2).
6.
With a gentle twisting motion, pull IAC straight out of
induction module body.
4
2
3
1
sm01629
1. IAC Connector [87A]
2. Screw (2)
3. IAC
4. Throttle cable bracket
Figure 4-51. IAC Removal/Installation: XL Models
2
1
sm01630
1. IAC mounting tab (2) (rotated 45 degrees)
2. Throttle cable bracket
Figure 4-52. Removing/Installing IAC: XL Models
INSTALLATION: XL MODELS
TORQUE VALUE
FASTENER
6.8 Nm
60
in-lbs
IAC mounting screw: XL
models
1.
See
. If re-using IAC (1), inspect O-ring (2) for
cuts, tears or signs of deterioration. Replace IAC if O-ring
is damaged.
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.
Clean all locking agent from the threads of the attachment
screws and holes. Blow debris from screw holes using
low-pressure compressed air.
3.
Apply a thin coat of
clean
engine oil to O-ring.
4.
See
. Rotate IAC approximately 45 degrees
clockwise so IAC mounting tab will clear throttle cable
bracket (2) when IAC is installed.
5.
With a gentle twisting motion, insert IAC into induction
module.
6.
Rotate IAC so that harness connector faces intake mani-
fold and mounting tab is underneath tab on throttle cable
bracket.
7.
Install IAC.
a.
See
. Apply a drop of LOCTITE 243
MEDIUM
STRENGTH
THREADLOCKER
AND
SEALANT (blue) to the threads of each screw (2).
b.
Install two screws (2).
c.
Use a six-point socket (not a Torx wrench). Tighten
to 60
in-lbs
(6.8 Nm).
8.
Plug harness connector [87B] into IAC connector [87A]
(1).
9.
Install air cleaner assembly. See
.
10. Install main fuse.
11. Close left side cover.
4-34 2013 Sportster Service: Fuel System
3
2
2
1
sm01632
1. IAC
2. O-ring
3. Pintle
Figure 4-53. IAC and O-ring
REMOVAL: XR 1200X
TOOL NAME
PART NUMBER
HEAT GUN
HD-25070
NOTE
It is not necessary to remove the fuel tank, air box or induction
module from the vehicle in order to replace the IAC.
Gasoline can drain from quick-connect fitting when
removing fuel line. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. Wipe up spilled fuel immediately and dispose of
rags in a suitable manner. (00267a)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Remove main fuse.
3.
See
. Unplug harness connector [87B] from
IAC connector [87A] (1).
NOTE
Screws (2) MUST be heated to soften the thread sealant and
avoid breakage during removal. Use ONLY HEAT GUN (Part
No. HD-25070) to heat the screws. NEVER use an open flame.
4.
Using a six-point socket (not a Torx wrench), remove two
screws (2) in the following order:
a.
Heat fastener nearest to throttle bracket for two
minutes using HEAT GUN (Part No. HD-25070).
Remove screw.
b.
Heat remaining screw for one minute and remove.
5.
See
. Grasp IAC and rotate counterclockwise
until IAC mounting tab (1) clears throttle cable bracket (2).
6.
With a gentle twisting motion, pull IAC straight out of
induction module body.
1
2
3
4
sm04969
1. IAC Connector [87A]
2. Screw (2)
3. IAC
4. Throttle cable bracket
Figure 4-54. IAC Removal/Installation: XR 1200X
2013 Sportster Service: Fuel System 4-35
1
2
sm04970
1. IAC mounting tab (2) (rotated 45 degrees)
2. Throttle cable bracket
Figure 4-55. Removing/Installing IAC: XR 1200X
INSTALLATION: XR 1200X
TORQUE VALUE
FASTENER
6.8 Nm
60
in-lbs
IAC mounting screw: XR
1200X
1.
See
. If re-using IAC (1), inspect O-ring (2) for
cuts, tears or signs of deterioration. Replace IAC if O-ring
is damaged.
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.
Clean all locking agent from the threads of the attachment
screws and holes. Blow debris from screw holes using
low-pressure compressed air.
3.
Apply a thin coat of
clean
engine oil to O-ring.
4.
See
. Rotate IAC approximately 45 degrees
counterclockwise so IAC mounting tab will clear throttle
cable bracket (2) when IAC is installed.
5.
With a gentle twisting motion, insert IAC into induction
module.
6.
Rotate IAC so that harness connector points straight down
and mounting tab is underneath tab on throttle cable
bracket.
7.
Install the IAC.
a.
See
. Apply a drop of LOCTITE 243
MEDIUM
STRENGTH
THREADLOCKER
AND
SEALANT (blue) to the threads of each screw (2).
b.
See
. Install two screws (2).
c.
Use a six-point socket (not a TORX wrench). Tighten
to 60
in-lbs
(6.8 Nm).
8.
Plug harness connector [87B] into IAC connector [87A]
(1).
9.
Connect fuel hose to fuel pump module. See
10. Install main fuse.
11. Close left side cover.
12. Turn on ignition switch and start motorcycle. Carefully
check for leaks around fuel hose fitting.
4-36 2013 Sportster Service: Fuel System
4.11
TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR
GENERAL
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
See
or
. The Temperature Manifold
Absolute Pressure (TMAP) sensor performs the dual functions
of monitoring air temperature and air pressure in the intake
manifold. See the electrical diagnostic manual.
sm06852
Figure 4-56. TMAP Location: XL Models
sm01622a
Figure 4-57. TMAP Location: XR 1200X
REMOVAL: XL MODELS
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)
Gasoline can drain from quick-connect fitting when
removing fuel line. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. Wipe up spilled fuel immediately and dispose of
rags in a suitable manner. (00267a)
1.
Remove main fuse.
2.
Remove air cleaner assembly. See
.
3.
Remove fuel rail and fuel injectors. See
. This will allow access to the two screws that
secure the induction module to the intake manifold.
4.
See
. Remove two screws (2) and separate
induction module from intake manifold. See
.
5.
See
. Pull induction module away from intake
manifold far enough so that TMAP sensor retaining bracket
(1) clears TMAP sensor body (2).
6.
Unplug harness connector [80B] from TMAP connector
[80A] (3).
7.
Grasp TMAP sensor and with a gentle twisting motion,
pull sensor straight up out of intake manifold body.
2013 Sportster Service: Fuel System 4-37
3
4
1
2
sm01623
1. TMAP sensor retaining bracket
2. TMAP sensor
3. Sensor connector [80A]
4. O-ring
Figure 4-58. TMAP Sensor Removal/Installation
INSTALLATION: XL MODELS
TORQUE VALUE
FASTENER
4.0 Nm
35
in-lbs
Induction module screw: XL
Models
1.
See
. If re-using TMAP sensor (1), inspect O-
ring (2) in groove of sensor for cuts, tears or signs of
deterioration. Replace if necessary.
2.
Apply a thin coat of
clean
engine oil to TMAP sensor O-
ring.
3.
See
. With a gentle twisting motion, insert
sensor (2) into intake manifold with connector [80A] (3)
facing rear cylinder head.
4.
Plug harness connector [80B] into TMAP sensor.
5.
Inspect O-ring (4) between induction module and intake
manifold for cuts, tears or signs of deterioration. Install
new
O-ring if necessary. Make certain O-ring is fully
seated in its grove in induction module body.
6.
Mate induction module to intake manifold. Secure with two
screws. Tighten to 35
in-lbs
(4.0 Nm).
7.
Install fuel injectors and fuel rail. See
8.
Install air cleaner assembly. See
.
To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)
Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)
Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)
9.
Connect fuel hose to fuel pump module.
10. Fill fuel tank. Carefully check for leaks around fuel pump
module. See
4.4 FUEL TANK: XL MODELS, Connecting
Fuel Hose and Filling Fuel Tank
11. Install main fuse.
12. Close left side cover.
1
2
sm01624
1. TMAP sensor
2. O-ring
Figure 4-59. TMAP Sensor
REMOVAL: XR 1200X
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
NOTE
See
. The TMAP sensor harness and TPS harness
are attached to inside of induction module cover. It is not
necessary to remove the retainer securing these harnesses to
the induction module cover in order to access TMAP sensor.
2.
Remove screws (3) and the wire form (1) and induction
module fastener (2).
4-38 2013 Sportster Service: Fuel System
3.
Carefully rotate induction module cover out of the way.
4.
Unplug TMAP sensor harness connector [80B].
5.
See
. Remove screw (2).
6.
Grasp TMAP sensor (1) and with a gentle twisting motion,
pull sensor straight up out of induction module body.
2
1
3
3
sm06774b
1. Fastener, wire form
2. Fastener, to induction module
3. Screws (2)
Figure 4-60. Induction Module Cover: XR 1200X
2
1
sm04998b
1. TMAP sensor [80A]
2. Screw
Figure 4-61. TMAP Sensor: XR 1200X
INSTALLATION: XR 1200X
TORQUE VALUE
FASTENER
9.0 Nm
80
in-lbs
TMAP sensor screw
27.1-32.5 Nm
20-24 ft-lbs
Induction module cover to cyl-
inder head fastener: XR
1200X
9.5-12.2 Nm
84-108
in-lbs
Induction module cover to
induction module fastener: XR
1200X
9.5-12.2 Nm
84-108
in-lbs
Wire form to induction module
cover fastener: XR 1200X
1.
If re-using TMAP sensor, inspect O-ring for cuts, tears or
signs of deterioration. Replace if necessary.
2.
Apply a thin coat of
clean
engine oil to TMAP sensor O-
ring.
3.
With a gentle twisting motion, insert sensor into induction
module with connector [80A] pointing down. Secure sensor
to induction module with screw. Tighten to 80
in-lbs
(9.0
Nm).
4.
Plug sensor harness connector [80B] into TMAP sensor.
5.
See
. Install the induction module cover.
a.
Rotate cover between cylinder heads.
b.
Install all fasteners finger-tight.
c.
Verify cover alignment before proceeding.
d.
Tighten socket head screws (3) to 20-24 ft-lbs (27.1-
32.5 Nm).
e.
Tighten fastener (2) to 84-108
in-lbs
(9.5-12.2 Nm).
f.
Tighten fastener (1) to 84-108
in-lbs
(9.5-12.2 Nm).
6.
Install main fuse.
2013 Sportster Service: Fuel System 4-39
4.12
OXYGEN (O2) SENSOR
GENERAL
See
. The O2 sensors are installed in threaded
bosses on the inboard side of the front and rear exhaust pipes.
For O2 sensor troubleshooting, see the electrical diagnostic
manual.
1
2
sm01642
1. Front O2 sensor
2. Rear O2 sensor
Figure 4-62. O2 Sensor Locations: XL Models
REMOVAL
TOOL NAME
PART NUMBER
OXYGEN SENSOR SOCKET
HD-48262
OXYGEN SENSOR SOCKET
HD-48647
1.
All Models:
See
. Disconnect the front O2
sensor connector:
a.
Remove the frame clip (2).
b.
Disconnect the sensor pin connector [138A] housing
(3) from the socket connector [138B] housing.
2.
XL Models:
See
. Disconnect the rear O2
sensor connector:
a.
Remove the rear O2 sensor connector [137] (2) from
the ECM caddy (1).
b.
Disconnect the rear O2 sensor pin connector [137A]
housing from the socket connector [137B] housing.
3.
XR 1200X:
Disconnect the rear O2 sensor pin connector
[137A] housing from the socket connector [137B] housing.
NOTE
If O2 sensors are to be reused:
•
Mark each sensor FRONT or REAR.
•
Do not damage the sensor wire harness.
4.
Remove the front and rear sensor:
a.
XL Models:
Use the OXYGEN SENSOR SOCKET
(Part No. HD-48262).
b.
XR 1200X:
Use the OXYGEN SENSOR SOCKET
(Part No. HD-48647).
1
2
3
sm01643
1. Front O2 sensor
2. Frame clip
3. O2 sensor connector [138]
Figure 4-63. Front O2 Sensor and Connector (XL shown)
1
2
sm06882
1. ECM caddy cover
2. O2 sensor
Figure 4-64. Rear Oxygen Sensor: XL Models
4-40 2013 Sportster Service: Fuel System
INSTALLATION
TOOL NAME
PART NUMBER
OXYGEN SENSOR SOCKET
HD-48262
OXYGEN SENSOR SOCKET
HD-48647
TORQUE VALUE
FASTENER
39.3-59.7 Nm
29-44 ft-lbs
O2 sensor
NOTES
•
Do not install O2 sensors that have been dropped or
impacted by other components. Damage to the sensor
element may have occurred.
•
New O2 sensors have threads coated with anti-seize
material.
•
If a sensor is being reused, apply a thin coat of ANTI-
SEIZE LUBRICANT to the sensor threads and install new
seal rings.
•
Do not use any other grease or sealant product on sensor
threads.
1.
Install the front and rear sensors:
a.
XL Models:
Use the OXYGEN SENSOR SOCKET
(Part No. HD-48262) to install the front and rear O2
sensors.
b.
XR 1200X:
Use the OXYGEN SENSOR SOCKET
(Part No. HD-48647) to install the front and rear O2
sensors.
2.
Tighten to 29-44 ft-lbs (39.3-59.7 Nm).
NOTE
The O2 connector must be clean and free of any dielectric
grease.
3.
All Models:
Route the front O2 wire harness:
a.
Connect the pin and socket connector [138] housings.
b.
Install the frame clip over the sensor harness, clutch
cable, and wiring harness on left frame down tube.
NOTE
Route rear O2 sensor harness toward left side in a loop away
from the exhaust system. Avoid contact with exhaust port or
exhaust pipe.
4.
XL Models:
Route the rear O2 sensor wire harness:
a.
Connect the pin and socket connector [137] housings.
b.
Route the wire harness and snap the connector into
the ECM caddy.
c.
Slide the caddy into place and tighten the fastener.
5.
XR 1200X:
Route sensor harness and connect pin and
socket connector [137] housings.
2013 Sportster Service: Fuel System 4-41
4.13
EXHAUST SYSTEM: XL MODELS
GENERAL
TOOL NAME
PART NUMBER
SNAP-ON WRENCH
PFSX916
To facilitate removing exhaust pipe header nuts, use SNAP-
ON WRENCH (Part No. PFSX916).
25
26
21
20
23
2
1
16
17
18
15
14
6
15
19
16
3
11
10
9
8
7
29
27
24
28
29
22
12
13
13
30
15
14
6
15
5
4
31
sm02198
23.
12.
1.
Screw
Heat shield, rear exhaust pipe
Muffler, front
2.
24.
13.
Muffler, rear
Engine sprocket cover
Worm drive clamp (5)
14.
3.
25.
Muffler heat shield (2) (HDI,
England, Japan, Brazil) (2)
Exhaust pipe, front
Screw
26.
4.
Washer
Exhaust pipe, rear
15.
5.
27.
Worm drive clamp (4)
Muffler interconnect bracket
Front O2 sensor assembly
28.
16.
6.
Rear O2 sensor assembly
Flanged bolt (4)
Torca muffler clamp assembly
(2)
29.
17.
Seal ring (2)
Screw (3)
7.
18.
Exhaust port gasket (2)
30.
Washer (3)
O2 sensor connectors (2):
[137], [138]
19.
8.
Muffler interconnect gasket (2)
Exhaust gasket retaining ring
(2)
31. Heat shield, rear exhaust pipe
(mid-control vehicles only)
20. Exhaust pipe clamp
9.
21.
Exhaust pipe flange (2)
Exhaust pipe clamp bracket
22.
10.
Acorn nut
Nut (4)
11. Heat shield, front exhaust
pipe
Figure 4-65. Exhaust System, All XL Models
4-42 2013 Sportster Service: Fuel System
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