Harley Davidson 2013 Sportster Models. Service Manual — page 1
MAINTENANCE
Fastener Torque Values in this Chapter. . . . . . . ..1-1
Repair and Replacement Procedures. . . . . . . . 1-4
Cleaning. . . . . . . . . . . . . . . . . . . ..1-5
Tool Safety. . . . . . . . . . . . . . . . . . ..1-5
Bulb Chart. . . . . . . . . . . . . . . . . . ...1-9
General. . . . . . . . . . . . . . . . . . . .1-10
Checking and Adding Oil. . . . . . . . . . . . ..1-15
Changing Oil and Filter. . . . . . . . . . . . . .1-16
Draining Oil Tank. . . . . . . . . . . . . ...1-16
Removing Oil Filter. . . . . . . . . . . . . 1-17
XL Models except XL 1200V. . . . . . . . . . . 1-19
Removal. . . . . . . . . . . . . . . . . 1-19
Installation. . . . . . . . . . . . . . . . .1-19
XL 1200V. . . . . . . . . . . . . . . . . . ..1-19
Removal. . . . . . . . . . . . . . . . . 1-19
Installation. . . . . . . . . . . . . . . . .1-20
XR 1200X. . . . . . . . . . . . . . . . . . .1-20
Removal. . . . . . . . . . . . . . . . . 1-20
Installation. . . . . . . . . . . . . . . . .1-21
Cleaning Filter Element. . . . . . . . . . . . . 1-22
Tread Wear. . . . . . . . . . . . . . . . 1-23
Tire Damage. . . . . . . . . . . . . . . ..1-24
Identify Wheel Spoke Groups. . . . . . . . . 1-25
Wheel Spoke Adjustment. . . . . . . . . . ..1-25
Free Play Adjustment. . . . . . . . . . . . . ...1-26
Transmission Lubrication. . . . . . . . . . . . ..1-27
Check Lubricant Level. . . . . . . . . . . ...1-27
Change Lubricant. . . . . . . . . . . . . ..1-28
Adjustment. . . . . . . . . . . . . . . . . . 1-29
Drive Belt Deflection. . . . . . . . . . . . . . .1-32
Gauging Deflection. . . . . . . . . . . . . 1-32
Adjustment. . . . . . . . . . . . . . . . .1-33
Operation. . . . . . . . . . . . . . . . ...1-35
Adjustment. . . . . . . . . . . . . . . . .1-35
1.14 CABLE AND CHASSIS LUBRICATION
III
T
ABLE
OF
CONTENTS
1.16 BRAKE PADS AND DISCS: XL MODELS
Inspection. . . . . . . . . . . . . . . . . . .1-40
1.17 BRAKE PADS AND DISCS: XR 1200X
Inspection. . . . . . . . . . . . . . . . . . .1-47
Brake Pad Replacement: Front. . . . . . . . . . 1-48
Removal. . . . . . . . . . . . . . . . . 1-48
Installation. . . . . . . . . . . . . . . . .1-49
Brake Pad Replacement: Rear. . . . . . . . . . .1-50
Removal. . . . . . . . . . . . . . . . . 1-50
Installation. . . . . . . . . . . . . . . . .1-51
Fall-Away. . . . . . . . . . . . . . . . . . ..1-55
Measurement. . . . . . . . . . . . . . . .1-55
Adjustment. . . . . . . . . . . . . . . . .1-55
Lubrication. . . . . . . . . . . . . . . . . . 1-55
Inspection. . . . . . . . . . . . . . . . . . .1-56
Checking Torques on Fasteners. . . . . . . . 1-56
1.21 ENGINE MOUNTS AND STABILIZER
LINKS
Inspection. . . . . . . . . . . . . . . . . . .1-58
Voltmeter Test. . . . . . . . . . . . . . . 1-61
Charging Battery. . . . . . . . . . . . . . . ...1-61
Safety Precautions. . . . . . . . . . . . . 1-61
Using a Battery Charger. . . . . . . . . . . 1-62
Exhaust System Leak Check. . . . . . . . . . . 1-65
Wheel Alignment. . . . . . . . . . . . . . . ...1-66
Checking Wheel Alignment. . . . . . . . . ...1-66
Adjusting Wheel Alignment. . . . . . . . . ...1-67
Front Fork: XR 1200X. . . . . . . . . . . . . ...1-68
Suspension Tuning: XR 1200X. . . . . . . . . . .1-70
Adjustment: XL 1200X/C/C ANV/CP/CA/CB/V. . ..1-72
Adjustment: XL 883R/L/N, XR 1200X. . . . . ...1-73
Lubrication System. . . . . . . . . . . . . . ...1-77
Electrical System. . . . . . . . . . . . . . . ..1-78
Transmission. . . . . . . . . . . . . . . . . 1-78
IV TABLE OF CONTENTS
TABLE OF CONTENTS
Brake Does Not Hold Normally. . . . . . . . .1-78
CHASSIS
Fastener Torque Values in this Chapter. . . . . . . ..2-1
Tables. . . . . . . . . . . . . . . . . . . . .2-9
Chassis. . . . . . . . . . . . . . . . . . 2-9
Wheels and Tires. . . . . . . . . . . . . ...2-11
2.3 VEHICLE IDENTIFICATION NUMBER
(VIN)
Vehicle Identification Number (VIN). . . . . . . . ..2-12
Checking Tire Runout. . . . . . . . . . . . . ...2-15
Lateral Runout. . . . . . . . . . . . . . ...2-15
Radial Runout. . . . . . . . . . . . . . . 2-16
Wheel Balancing. . . . . . . . . . . . . . . ...2-16
Static vs Dynamic. . . . . . . . . . . . . ..2-16
Weights. . . . . . . . . . . . . . . . . ..2-16
Rear Wheel. . . . . . . . . . . . . . . . . ...2-23
Sealed Wheel Bearings. . . . . . . . . . . . . 2-25
Wheel Lacing: Straight Flange Hub, Dual Hole Circle. ..2-31
2.7 CHECKING AND TRUING WHEELS
Cast Wheel Runout. . . . . . . . . . . . . . ...2-33
Radial Runout. . . . . . . . . . . . . . . 2-35
Lateral Runout. . . . . . . . . . . . . . ...2-35
2.8 FRONT BRAKE MASTER CYLINDER
2.9 FRONT BRAKE CALIPER: XL MODELS
2.10 FRONT BRAKE CALIPER: XR 1200X
2.11 REAR BRAKE MASTER CYLINDER: XL
MODELS
2.12 REAR BRAKE MASTER CYLINDER: XR
1200X
2.13 REAR BRAKE MASTER CYLINDER
RESERVOIR
Removal: XL Models. . . . . . . . . . . . . . .2-69
TABLE OF CONTENTS V
TABLE OF CONTENTS
2.14 REAR BRAKE CALIPER: XL MODELS
2.15 REAR BRAKE CALIPER: XR 1200X
Front Brake Line. . . . . . . . . . . . . . . ...2-86
Removal. . . . . . . . . . . . . . . . . 2-86
Installation. . . . . . . . . . . . . . . . .2-86
Front Brake Line Routing. . . . . . . . . . . . ..2-88
Rear Brake Line: XL Models. . . . . . . . . . . .2-90
Removal. . . . . . . . . . . . . . . . . 2-91
Installation. . . . . . . . . . . . . . . . .2-91
Rear Brake Line: XR 1200X. . . . . . . . . . . .2-92
Removal. . . . . . . . . . . . . . . . . 2-92
Installation. . . . . . . . . . . . . . . . .2-93
Changing Fork Oil: XL Models. . . . . . . . . . ..2-98
Removal. . . . . . . . . . . . . . . . . . . 2-99
Disassembly. . . . . . . . . . . . . . . . . .2-99
Drain Fork Oil. . . . . . . . . . . . . . . 2-99
Fork Disassembly. . . . . . . . . . . . . ..2-99
Installation. . . . . . . . . . . . . . . . . ...2-102
Installation. . . . . . . . . . . . . . . . . ...2-108
2.21 FORK STEM AND BRACKET
ASSEMBLY
2.22 BELT GUARD AND DEBRIS
DEFLECTOR
Belt Guard: XL Models. . . . . . . . . . . . . 2-111
Removal. . . . . . . . . . . . . . . . ..2-111
Installation. . . . . . . . . . . . . . . ...2-111
Debris Deflector: XL Models. . . . . . . . . . ...2-111
Removal. . . . . . . . . . . . . . . . ..2-111
Installation. . . . . . . . . . . . . . . ...2-111
Belt Guard: XR 1200X. . . . . . . . . . . . . 2-111
Removal. . . . . . . . . . . . . . . . ..2-111
Installation. . . . . . . . . . . . . . . ...2-111
Debris Deflector: XR 1200X. . . . . . . . . . ...2-112
Removal. . . . . . . . . . . . . . . . ..2-112
Installation. . . . . . . . . . . . . . . ...2-112
Removal. . . . . . . . . . . . . . . . ..2-118
Installation. . . . . . . . . . . . . . . ...2-118
Lower Front Stabilizer Link. . . . . . . . . . . .2-118
Removal. . . . . . . . . . . . . . . . ..2-118
Installation. . . . . . . . . . . . . . . ...2-118
Rear Stabilizer Link. . . . . . . . . . . . . . .2-119
Removal. . . . . . . . . . . . . . . . ..2-119
Installation. . . . . . . . . . . . . . . ...2-119
VI TABLE OF CONTENTS
TABLE OF CONTENTS
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
12. Test ride motorcycle. Repeat the bleeding procedure if
brakes feel spongy.
Table 2-18. Fluid Level
SPECIFICATION
ITEM
Boss or ridge
Front reservoir
Ledge or range window
Rear reservoir
Table 2-19. Torque Specifications
TORQUE
COMPONENT
35-61
in-lbs
(4.0-6.9 Nm)
Bleeder
9-17
in-lbs
(1.0-2.0 Nm)
Front cover
Hand tighten
Rear cover
2013 Sportster Service: Chassis 2-95
2.18
LEFT SIDE COVER
GENERAL
See
. The left side cover provides access to the
battery (1), fuses (3, 4) and diagnostic connector (5).
XL Models:
The left side cover is secured by two barrel clips
secured to two upper slots that fit into socket clips mounted to
the frame.
XR 1200X:
The left side cover is secured by two molded-in
posts that fit into grommets.
The side cover is also secured by a bottom slot that fits onto
a mounting tab on the battery tray.
NOTE
The left side cover does not need to be completely removed
to access the battery or fuses.
5
2
4
3
1
sm06647
1. Battery
2. Positive (+) battery terminal (under protective
rubber boot)
3. Main fuse and holder
4. System fuses and relays
5. Diagnostic connector (data link)
Figure 2-133. Main Fuse and Battery Location: All Models
OPENING LEFT SIDE COVER
1.
Place a clean, dry cloth over rear brake master cylinder
reservoir and left passenger foot peg (if equipped). This
will protect left side cover from damage.
NOTE
On XL models, disengage the rear clip first for easier opening.
2.
See
or
. Grasp top corners of
side cover. Gently pull away from plastic socket clips (XL
models) or grommets (XR 1200X) on frame.
2
4
1
1
2
3
sm01416a
1. Socket clips (on frame)
2. Side cover barrel clips (top)
3. Mounting tab (on battery tray)
4. Side cover barrel clips mounting screw (bottom)
Figure 2-134. Left Side Cover: XL Models
2
1
1
sm06777
1. Side cover mounting posts (top)
2. Side cover mounting slot (bottom)
Figure 2-135. Left Side Cover: XR 1200X
2-96 2013 Sportster Service: Chassis
1
3
4
2
1
2
sm01417a
1. Battery tray assembly
2. Mounting tab
3. Side cover (closed)
4. Side cover (open)
Figure 2-136. Left Side Cover Bottom Mount: All Models
3.
See
. Rotate top of cover away from motor-
cycle and down slightly. Mounting slot on cover will slide
down mounting tab (2) on battery tray assembly (1). Side
cover (4) will rest on top of rear brake master cylinder
reservoir and left passenger footrest (if equipped).
Leaning or placing tools on side cover could cause damage
to cover and/or mounting tab on battery tray. (00523b)
CLOSING LEFT SIDE COVER
1.
Grasp top corners of side cover. While rotating top of cover
up toward motorcycle, gently pull cover up so that
mounting slot slides up mounting tab.
2.
Press top of side cover into place:
a.
XL models:
See
. Line up barrel clips
on side cover with socket clips on motorcycle frame,
aligning with front clip first. Press top of side cover
into clips until you hear an audible snap.
b.
XR 1200X:
See
. Line up molded-in posts
in top of side cover with mounting grommets on
motorcycle frame. Press posts in side cover into
grommets until snug.
NOTE
Side cover should snap into place with minimal pressure. Using
excessive force or striking side cover to close it can damage
mounting clips (XL models) or molded-in posts (XR 1200X).
REMOVING LEFT SIDE COVER
1.
See
or
. Grasp top corners of
side cover. Gently pull away from plastic mounting clips
(XL models) or grommets (XR 1200X) on frame.
NOTE
On XL models, disengage the rear clip first for easier opening.
2.
See
. Lift side cover up and tilt cover to the
rear of the motorcycle. With a slight back and forth rocking
motion, pull up gently until cover disengages from
mounting tab on battery tray.
sm01419a
Figure 2-137. Removing Left Side Cover: All Models (XL
Model Shown)
INSTALLING LEFT SIDE COVER
1.
Position side cover over battery tray assembly. Align slot
in bottom of cover to mounting tab on battery tray.
2.
Gently guide the side cover down over mounting tab.
3.
Close the left side cover. See
2013 Sportster Service: Chassis 2-97
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