Harley Davidson 2013 Sportster Models. Service Manual — page 27

2

1

4

6

5

3

sm01656

1. Fuel supply hose fitting
2. Fuel tank quick-connect fitting
3. Fuel pressure gauge adapter
4. Adapter quick-connect fitting
5. Pressure adapter/Schroeder valve fitting
6. Fuel valve (closed position)

Figure 4-82. Assembling Adapter, Gauge and Fuel Supply

Hose to Fuel Tank: All Models

sm01657

Figure 4-83. Fuel Pressure Gauge Installed: All Models

Table 4-3. Fuel Pressure Test

SOLUTION

CAUSE

RESULTS

Replace.

Restricted fuel filter

Less than: 55 psi (380 kPa)

Clean.

Restricted pump inlet screen

Clear.

Restricted fuel line or hose to gauge

Replace.

Faulty fuel pump

Clear.

Restricted check valve fitting

Repair or replace as necessary.

Leak inside tank (hose or coupling)

Replace.

Faulty pressure regulator

Operating fuel pressure

Steady at: 55-62 psi (380-425 kPa)

Replace as necessary.

Check valve fitting and fuel tank

More than: 62 psi (425 kPa)

Replace.

Fuel pressure regulator

Return to Service

1.

Position the air bleed tube in a suitable container. Open
the air bleed petcock to relieve the fuel system pressure
and purge the pressure gauge of gasoline.

Gasoline can drain from the adapter when gauge is
removed. 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. (00254a)

2.

Remove fuel pressure gauge from the adapter. Install
protective cap over Schroeder valve.

Gasoline can drain from the fuel line and adapter when
removed. 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. (00255a)

3.

Pull up on knurled sleeve of the fuel pressure gauge
adapter quick-connect fitting and remove vehicle's fuel
supply hose from adapter. Release adapter from fuel tank.

HOME

2013 Sportster Service: Fuel System 4-59

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)

4.

Push up on release sleeve of fuel pump quick-connect
fitting and push the fuel hose fitting into quick-connect fit-
ting. Pull down on release sleeve to lock. Tug on fuel hose
fitting to verify that it is locked.

HOME

4-60 2013 Sportster Service: Fuel System

4.19

INTAKE LEAK TEST

GENERAL

Do not allow open flame or sparks near propane. Propane
is extremely flammable, which could cause death or ser-
ious injury. (00521b)

Read and follow warnings and directions on propane
bottle. Failure to follow warnings and directions can result
in death or serious injury. (00471b)

NOTES

•

To prevent false readings, keep air cleaner cover installed
when performing test.

•

Do not direct propane into air cleaner. It will cause false
readings.

•

Be careful when testing vehicle with Screamin' Eagle air
cleaner assembly. This type of air cleaner has an open
backplate. Even with air cleaner cover on, directing nozzle
too close to backplate can give false readings.

LEAK TESTER

TOOL NAME

PART NUMBER

PROPANE ENRICHMENT KIT

HD-41417

Parts List

•

Standard 14 oz. propane cylinder.

•

PROPANE ENRICHMENT KIT (Part No. HD-41417).

Tester Assembly

1.

See

Figure 4-84

. Make sure valve knob (6) is closed (fully

clockwise).

2.

Screw valve assembly (5) onto propane bottle (1).

Tester Adjustment

1.

See

Figure 4-84

. Press and hold trigger button (8).

2.

Slowly open valve knob (6) until pellet in flow gauge (7)
rises 5-10 SCFH on gauge.

3.

Release trigger button.

1

8

5

9

3

2

7

4

6

sm02629

1. Propane bottle
2. Nozzle
3. Copper tube
4. Hose
5. Valve assembly
6. Valve knob
7. Flow gauge
8. Trigger button
9. Hanger

Figure 4-84. Leak Tester

PROCEDURE

1.

Start engine.

2.

Warm up engine to operating temperature.

NOTE

Do not direct propane stream toward air cleaner. If propane
enters air cleaner, a false reading will be obtained.

3.

See

Figure 4-85

. Aim nozzle (3) toward possible sources

of leak such as intake manifold mating surfaces.

4.

Press and release trigger button (2) to dispense propane.
Tone of engine will change when propane enters source
of leak. Repeat as necessary to detect leak.

HOME

2013 Sportster Service: Fuel System 4-61

5.

When test is finished, close valve knob (turn knob fully
clockwise).

3

2

1

sm01661

1. Propane bottle
2. Trigger button
3. Nozzle

Figure 4-85. Checking for Leaks: All Models

HOME

4-62 2013 Sportster Service: Fuel System

4.20

EVAPORATIVE EMISSIONS CONTROL

GENERAL

Motorcycles sold in some markets have an evaporative (EVAP)
emissions control system.

See

Figure 4-86

. The EVAP functions in the following manner:

•

Hydrocarbon vapors in the fuel tank (2, 10) are vented
through the vapor valve (4) or vent fitting (9). The vapors
are stored in the charcoal canister (3). When tipped, the
valve closes. Gasoline cannot leak into the charcoal can-
ister from the vapor valve hoses (5, 6).

•

When the engine is running, intake negative pressure
(vacuum) slowly draws hydrocarbon vapors from the
charcoal canister through the purge hose (7). These
vapors pass through the intake and are burned as part of
normal combustion in the engine.

Keep evaporative emissions vent lines away from exhaust
and engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00266a)

NOTE

The EVAP system is designed to operate with a minimum of
maintenance. Check that all hoses are connected and correctly
routed. They cannot be pinched, kinked, cracked or torn.
Improper connections could leak charcoal from canister.

3

3

6

6

7

7

10

9

8

2

4

8

5

1

1

sm03399a

1. Induction module
2. Fuel tank (XL models only)
3. Charcoal canister
4. External vapor valve (XL models only)
5. Fuel tank-to-vapor valve hose
6. Vapor valve-to-canister hose
7. Purge hose
8. Fuel supply hose
9. Vent fitting (XR 1200X)
10. Fuel tank (XR 1200X)

Figure 4-86. Evaporative Emissions Control System

(typical)

HOME

2013 Sportster Service: Fuel System 4-63

CHARCOAL CANISTER

TORQUE VALUE

FASTENER

23.1-29.9 Nm

17-22 ft-lbs

EVAP canister mounting
bracket screw

23.0-29.8 Nm

17-22 ft-lbs

Master cylinder mounting
bracket, rear, screw: XL
models

23.1-29.9 Nm

17-22 ft-lbs

EVAP canister mounting
bracket screw

4.1-6.8 Nm

36-60

in-lbs

EVAP canister clip mounting
screw

4.0-5.1 Nm

35-45

in-lbs

EVAP canister guard screw

The charcoal canister is mounted to a bracket attached to the
rear brake master cylinder bracket, near the bottom of the
frame in front of the rear fork pivot point.

Removal

1.

See

Figure 4-87

. Remove two screws (1) and canister

guard (2).

2.

Mark the two hoses (9, 10) connected to charcoal canister
(6). Disconnect hoses from canister.

3.

Press the locking tabs at the left end of canister clip (5).
Slide canister towards left side of vehicle until it disen-
gages from canister clip.

4.

Remove two screws (7) and washers (8) to detach canister
clip from canister mounting bracket (3).

5.

XL Models:

If canister mounting bracket requires

repair/replacement, proceed as follows:

a.

Remove two screws (13) and washers (14) securing
rear master cylinder to mounting bracket. This will
allow you to move the rear master cylinder to access
the remaining fasteners.

b.

Remove two screws (4) to detach canister mounting
bracket from rear master cylinder mounting bracket.

6.

XR 1200X:

See

Figure 4-88

. If canister mounting bracket

requires repair/replacement, remove two screws (2) to
detach canister mounting bracket from frame.

NOTE

It is not necessary to remove brake line clamp screw (1).

4

8

9

3

5

6

7

10

11

12

1

2

13

14

sm06718

1. Screw (2)
2. Canister guard
3. Canister mounting bracket
4. Screw (2)
5. Canister clip
6. Charcoal canister
7. Screw (2)
8. Washer (2)
9. Purge hose from induction module
10. Vent hose from vapor valve
11. Rear master cylinder bracket
12. Rear master cylinder
13. Screw (2)
14. Washer (2)

Figure 4-87. Charcoal Canister Mounting (typical)

HOME

4-64 2013 Sportster Service: Fuel System

4

1

3

5

2

2

sm04977

1. Screw
2. Canister mounting bracket screws (2)
3. Canister mounting bracket
4. Fuel tank-to-canister hose
5. Canister-to-induction module hose

Figure 4-88. Charcoal Canister Mount: XR 1200X

Installation

NOTE

XL Models: Verify that the EVAP canister mounting hardware
does not contact the rear stabilizer ground strap.

1.

XL Models:

See

Figure 4-87

. If canister mounting bracket

(3) was removed, proceed as follows:

a.

Attach bracket (3) to rear master cylinder mounting
bracket and frame with two screws (4). Tighten to 17-
22 ft-lbs (23.1-29.9 Nm).

b.

Apply one or two drops of LOCTITE 243 to screws
(13). Install rear master cylinder (12) to mounting
bracket (11) with screws and washers (14). Tighten
to 17-22 ft-lbs (23.0-29.8 Nm).

2.

XR 1200X:

See

Figure 4-88

. If canister mounting bracket

(3) was removed, proceed as follows:

a.

Apply

LOCTITE

243

MEDIUM

STRENGTH

THREADLOCKER AND SEALANT (blue) to the
threads of the mounting screws (2).

b.

Install bracket and tighten screws (2) to 17-22 ft-lbs
(23.1-29.9 Nm).

3.

See

Figure 4-87

. Attach canister clip (5) to canister

mounting bracket with two screws (7) and two washers
(8). Tighten to 36-60

in-lbs

(4.1-6.8 Nm).

4.

Starting at left side of canister clip, slide charcoal canister
(6) to the right until tabs on canister clip lock canister in
place. Bend tabs outward somewhat if canister is not held
securely.

5.

See

Figure 4-89

. Connect two hoses (1, 2), marked during

disassembly, to their proper fittings on canister.

6.

See

Figure 4-87

. Install canister guard (2) using two

screws (1). Tighten to 35-45

in-lbs

(4.0-5.1 Nm).

2

1

3

sm01648

1. Purge hose from induction module
2. Vent hose from fuel tank and vapor valve
3. Clean air port (no hose connection)

Figure 4-89. Charcoal Canister Connections

VAPOR VALVE: XL MODELS

Removal

NOTES

•

XL Models: The vapor valve is located under the left side
cover in a clip molded into the ECM caddy.

•

XR 1200X: The vapor valve is incorporated in the fuel tank
filler housing. See

4.5 FUEL TANK: XR 1200X

.

1.

Open left side cover. See

2.18 LEFT SIDE COVER

.

2.

See

Figure 4-90

. Carefully remove vapor valve (2).

3.

Mark two hoses (1, 3) connected to upper and lower fittings
of vapor valve. Remove hoses from fittings.

NOTE

On non-EVAP system models, charcoal canister is absent and
bottom hose of vapor valve is vented to the atmosphere.

Installation

Keep vent and vapor valve lines away from exhaust and
engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00263a)

NOTE

Mount the vapor valve in an upright position with the longer
fitting positioned at the top or excessive fuel vapor pressure
may build up within the fuel tank. Mounting the vapor valve
upside down will result in fuel flow problems.

HOME

2013 Sportster Service: Fuel System 4-65

1.

See

Figure 4-90

. Hold vapor valve (2) in an upright position

with the long necked end pointing up. Insert top fitting of
vapor valve into fuel tank-to-vapor valve hose (1). Install
bottom vapor valve fitting into vapor valve-to-canister hose
(3).

2.

Carefully push body of vapor valve into clip (4) molded
into the ECM caddy (6).

NOTE

Do NOT force vapor valve into clip. Forcing valve in to clip
could cause clip to break, necessitating replacement of the
ECM caddy.

3.

Close left side cover.

1

2

3

6

4

5

3

2

1

7

8

sm06582a

1. Fuel tank-to-vapor valve hose
2. Vapor valve
3. Vapor-valve-to-canister hose
4. Vapor valve clip
5. Fuel pump harness
6. ECM caddy
7. To fuel tank
8. To charcoal canister

Figure 4-90. Vapor Valve and Hose Routing: XL EVAP

Models

HOSE ROUTING

Induction Module

XL Models:

Remove the fuel tank and air cleaner/backplate

assembly to access the induction module.

XR 1200X:

See

Figure 4-91

. Route the evaporative emissions

control hose to the purge hose fitting (2) on the induction
module (1).

2

1

sm06565

1. Induction module
2. Purge hose (to canister) fitting

Figure 4-91. Emissions Hose Routing at Induction Module

Canister Hose Routings: XL Models

1.

See

Figure 4-92

. Connect the vapor valve-to-canister hose

(1) to the canister lower fitting marked TANK and the
canister-to-induction module purge hose (2) to the upper
fitting labeled CARB.

2.

Route the vapor valve-to-canister hose:

a.

Under the frame.

b.

Behind the rear brake master cylinder bracket.

c.

Up the frame tube in front of the rear fork pivot.

d.

Inside the electrical caddy to the vapor valve inside
the left side cover.

3.

Connect the vapor valve-to-canister hose to the vapor
valve.

4.

Connect fuel tank-to-vapor valve hose the the vapor valve.

5.

Route the fuel tank-to-vapor valve hose forward along the
left side of frame backbone and connect to fitting on bottom
of fuel tank.

6.

Route the canister-to-induction module purge hose:

a.

Loop behind the brake fluid lines and around the
master cylinder.

b.

Behind the frame.

c.

Between the rear fork and the rear fork pivot.

d.

Behind the oil lines and up behind the oil tank.

e.

Route canister-to-induction module purge hose up
right side of frame rear downtube.

f.

Loop the hose over the wire harness caddy and for-
ward along the caddy and the frame backbone.

g.

Connect the hose to the induction module.

NOTE

Position the hose against the engine sub-harness and as far
from the rear rocker cover as possible.

HOME

4-66 2013 Sportster Service: Fuel System

7.

See

Figure 4-93

. Secure the hose to the holes in the wire

harness caddy with barbed cable straps.

1

1

2

2

sm06826

1. Tank to vapor valve
2. CARB to induction module

Figure 4-92. EVAP Canister and Hose Routing

sm06827

Figure 4-93. Cable Strap Locations

Canister Hose Routings: XR 1200X

1.

See

Figure 4-94

. Route both hoses up past canister mount

and between rear fork pivot point and rear end of crank-
case as shown.

2.

See

Figure 4-95

. Route fuel vapor hose (4) up along left

side of frame rear downtube and outside the left electrical
caddy. Connect to vapor tube (2).

3.

Connect vapor tube (2) to fitting (1) on fuel tank filler
housing and place in channel on top of fuel tank.

4.

Secure to electrical caddy with barbed clamp (3).

5.

See

Figure 4-96

. Route canister-to-induction module purge

hose (1) up right side of frame rear downtube. Continue
routing hose forward along right side of frame backbone
tube and down, connecting hose to induction module fitting
(3).

6.

Secure hose to channels on rear end of right wire harness
caddy (4). Verify that hose is positioned up against engine
sub-harness. Secure hose and harness with clamp (2).

7.

Connect hoses to labeled fittings on left side of charcoal
canister.

4

1

3

5

2

2

sm04977

1. Screw
2. Canister mounting bracket screws (2)
3. Canister mounting bracket
4. Fuel tank-to-canister hose
5. Canister-to-induction module hose

Figure 4-94. Charcoal Canister Mount: XR 1200X

1

2

3

4

sm05436

1. Vapor fitting
2. Vapor tube
3. Clamp
4. Vapor hose

Figure 4-95. Vapor Hose Routing

HOME

2013 Sportster Service: Fuel System 4-67

1

4

2

3

sm05437a

1. Purge hose
2. Clamp
3. Induction module fitting
4. Right wire harness caddy

Figure 4-96. Purge Hose Routing

HOME

4-68 2013 Sportster Service: Fuel System

TABLE OF CONTENTS

SUBJECT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE NO.

5.1 FASTENER TORQUE VALUES. . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 SPECIFICATIONS: DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 PRIMARY COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.4 PRIMARY DRIVE AND CLUTCH: XL MODELS. . . . . . . . . . . . . . . . . . 5-8
5.5 PRIMARY DRIVE AND CLUTCH: XR 1200X. . . . . . . . . . . . . . . . . . ..5-15
5.6 DRIVE BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.7 TRANSMISSION POWER FLOW. . . . . . . . . . . . . . . . . . . . . . . 5-28
5.8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL. . . . . . . . . . . . . ..5-30
5.9 TRANSMISSION REMOVAL AND DISASSEMBLY. . . . . . . . . . . . . . . . 5-33
5.10 TRANSMISSION ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . ...5-37
5.11 MAIN DRIVE GEAR AND BEARING. . . . . . . . . . . . . . . . . . . . . .5-39
5.12 TRANSMISSION RIGHT CASE BEARINGS. . . . . . . . . . . . . . . . . . .5-49
5.13 TRANSMISSION LEFT CASE BEARINGS. . . . . . . . . . . . . . . . . . ...5-50
5.14 TRANSMISSION INSTALLATION. . . . . . . . . . . . . . . . . . . . . . ..5-51
5.15 TRANSMISSION SPROCKET. . . . . . . . . . . . . . . . . . . . . . . ...5-56

DRIVE/TRANSMISSION

5.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

5.6 DRIVE BELT, Drive Belt: XL Models

129-142 Nm

95-105 ft-lbs

Axle, rear, nut

5.6 DRIVE BELT, Drive Belt: XR 1200X

129-142 Nm

95-105 ft-lbs

Axle, rear, nut

5.3 PRIMARY COVER, Installation

4.1-12.2 Nm

36-108

in-lbs

Clutch cable fitting

5.3 PRIMARY COVER, Installation

10.3-13.6 Nm

90-120

in-lbs

Clutch inspection cover screws

5.14 TRANSMISSION INSTALLATION, Shifter
Shaft Installation

44.8-50.2 Nm

33-37 ft-lbs

Countershaft retaining screw

5.14 TRANSMISSION INSTALLATION, Assembling
Crankcases

20.3-25.8 Nm

15-19 ft-lbs

Crankcase fastener

5.5 PRIMARY DRIVE AND CLUTCH: XR
1200X, Installation

210.0-224.0 Nm

155-165 ft-lbs

Engine sprocket bolt: XR 1200X

5.4 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Installation

326-353 Nm

240-260 ft-lbs

Engine sprocket nut: XL Models

5.6 DRIVE BELT, Drive Belt: XL Models

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket fastener: XL
Models

5.15 TRANSMISSION SPROCKET, Installation

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket fastener: XR
1200X

5.15 TRANSMISSION SPROCKET, Installation

61-68 Nm

45-50 ft-lbs

Footrest mount fastener

5.14 TRANSMISSION INSTALLATION, Installation

10.2-12.4 Nm

90-110

in-lbs

Gear detent assembly screw

5.3 PRIMARY COVER, Installation

21.7-27.1 Nm

16-20 ft-lbs

Gear shift lever pinch screw

5.6 DRIVE BELT, Idler Pulley: XR 1200X

44.7-47.5 Nm

33-35 ft-lbs

Idler pulley bracket flanged nut: XR
1200X

5.6 DRIVE BELT, Idler Pulley: XR 1200X

95-109 Nm

70-80 ft-lbs

Idler pulley fastener: XR 1200X

5.15 TRANSMISSION SPROCKET, Installation

40.7-44.8 Nm

30-33 ft-lbs

Muffler interconnect bracket mounting
screw: XR 1200X

5.14 TRANSMISSION INSTALLATION, Assembling
Crankcases

13.6-20.3 Nm

120-180

in-lbs

Neutral indicator switch

5.3 PRIMARY COVER, Installation

27.1-33.9 Nm

20-25 ft-lbs

Primary chain adjuster locknut

5.3 PRIMARY COVER, Installation

19.0-40.7 Nm

14-30 ft-lbs

Primary chaincase drain plug

5.3 PRIMARY COVER, Installation

11.3-13.6 Nm

100-120

in-lbs

Primary chain cover screw

5.6 DRIVE BELT, Drive Belt: XL Models

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and lower
screws

5.6 DRIVE BELT, Idler Pulley: XR 1200X

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and lower
screws

5.6 DRIVE BELT, Drive Belt: XR 1200X

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and lower
screws

5.15 TRANSMISSION SPROCKET, Installation

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and lower
screws

5.15 TRANSMISSION SPROCKET, Installation

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and lower
screws

5.6 DRIVE BELT, Idler Pulley: XR 1200X

40.7-44.8 Nm

30-33 ft-lbs

Sprocket cover, rear screw

5.6 DRIVE BELT, Drive Belt: XR 1200X

40.7-44.8 Nm

30-33 ft-lbs

Sprocket cover, rear screw

5.15 TRANSMISSION SPROCKET, Installation

40.7-44.8 Nm

30-33 ft-lbs

Sprocket cover, rear screw

HOME

2013 Sportster Service: Drive/Transmission 5-1

NOTES

TORQUE VALUE

FASTENER

5.4 PRIMARY DRIVE AND CLUTCH: XL
MODELS, Installation

67.8-81.3 Nm

50-60 ft-lbs

Transmission mainshaft nut: XL Models

5.5 PRIMARY DRIVE AND CLUTCH: XR
1200X, Installation

67.8-81.3 Nm

50-60 ft-lbs

Transmission mainshaft nut: XR 1200X

5.15 TRANSMISSION SPROCKET, Installation

10.3-13.6 Nm

90-120

in-lbs

Transmission sprocket lockplate fastener

5.15 TRANSMISSION SPROCKET, Installation/Ini-
tial torque plus 30-40 degrees.

68 Nm

50 ft-lbs

Transmission sprocket nut

HOME

5-2 2013 Sportster Service: Drive/Transmission

5.2

SPECIFICATIONS: DRIVE

SPORTSTER SPECIFICATIONS

Table 5-1. Sprocket Teeth

NUMBER OF TEETH

ITEM

DRIVE

XR 1200X

XL 1200 MODELS

XL 883 MODELS

U.S./WORLD

WORLD

U.S.

WORLD

U.S.

34

38

38

34

34

Engine

Primary

57

57

57

57

57

Clutch

28

30

29

29

29

Transmission

Final

68

68

68

68

68

Rear wheel

Table 5-2. Overall Drive Ratios

XR 1200X

XL 1200 MODELS

XL 883 MODELS

GEAR

U.S./WORLD

WORLD

U.S.

ALL

10.782

9.004

9.315

10.407

1st

7.702

6.432

6.653

7.436

2nd

5.728

4.783

4.948

5.530

3rd

4.748

3.965

4.102

4.583

4th

4.071

3.400

3.517

3.931

5th

NOTE

Service wear limits are given as a guideline for measuring
components that are not new. For measurement specifications

not given under SERVICE WEAR LIMITS, see NEW COMPON-
ENTS.

Table 5-3. Clutch Pack Plate Specifications

SERVICE WEAR LIMIT

NEW COMPONENTS

ITEM

mm

in

mm

in

CLUTCH PLATE THICKNESS

2.0200

0.0795

2.2000 ± 0.0800

0.8661 ± 0.0031

Friction plate (fiber)

N/A

N/A

1.6000

0.0629

Steel plate

MAXIMUM ALLOWABLE WARPAGE

0.1500

0.0059

N/A

N/A

Friction plate (fiber)

0.1500

0.0059

N/A

N/A

Steel plate

HOME

2013 Sportster Service: Drive/Transmission 5-3

5.3

PRIMARY COVER

REMOVAL

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

1.

Disconnect the negative (-) battery cable from the engine
stud on the back of the crankcase behind the starter motor
assembly. See

1.22 BATTERY MAINTENANCE

.

2.

Remove left side rider footrest and mounting bracket
assembly.

a.

Models with Mid-mount Controls:

See

2.40 RIDER

FOOT CONTROLS: XL MID-MOUNT CONTROLS

or

2.42 RIDER FOOT CONTROLS: XR 1200X

.

b.

Models with Forward Controls:

See

2.41 RIDER

FOOT CONTROLS: XL FORWARD CONTROLS

.

3.

See

Figure 5-1

. Place a drain pan under the engine.

Remove drain plug (1) and drain lubricant from primary
drive housing.

NOTE

Dispose of primary lubricant in accordance with local regula-
tions.

4.

Loosen locknut (2). Turn chain adjuster screw (3) counter-
clockwise to relax primary chain tension.

5.

Remove gear shift lever (4) and rubber washer from
transmission shifter shaft.

6.

Loosen the clutch cable tension at the clutch cable
adjuster.

7.

Remove the clutch inspection cover (5).

8.

See

Figure 5-2

. Remove the quad ring (1) from the groove

in the primary cover. Discard the quad ring.

9.

Slide hex lockplate (2) and attached spring from flats of
adjusting screw.

10. Turn adjusting screw clockwise to release ramp assembly

(3) and coupling mechanism. As the adjusting screw is
turned, ramp assembly moves forward. Remove nut from
end of adjusting screw.

11. Remove hook (4) of ramp (3) from cable coupling (5).

Remove clutch cable end from slot in coupling. Remove
coupling and ramp assembly.

12. See

Figure 5-4

. Turn cable end fitting counterclockwise

to remove clutch cable lower section from primary cover.
Remove and discard O-ring from cable end fitting.

13. Remove sixteen screws with captive washers securing

primary cover to engine crankcase. Remove cover and
gasket. Discard gasket.

14. See

Figure 5-5

. Remove and discard shifter shaft oil seal.

1

1

4

2

5

3

sm06915

1. Primary drain plug
2. Locknut
3. Adjuster screw
4. Shift lever
5. Clutch inspection cover

Figure 5-1. Primary Cover

1

4

2

5

3

sm06901

1. Quad ring
2. Hex lockplate
3. Ramp assembly
4. Hook
5. Cable coupling

Figure 5-2. Clutch Release Ramp

HOME

5-4 2013 Sportster Service: Drive/Transmission

3

5

4

2

1

sm06898

1. Screw
2. Inspection Cover
3. Quad ring
4. Screw
5. Gasket

Figure 5-3. Primary Cover

sm06900

Figure 5-4. Clutch Cable Fitting

sm07177

Figure 5-5. Shifter Shaft Oil Seal

CLUTCH RELEASE RAMP

1.

Clean all parts in cleaning solvent. Dry with a clean, lint-
free cloth.

2.

See

Figure 5-6

. Inspect three balls (1) and ball socket

surfaces of inner ramp (2) and outer ramp (3). Replace
parts as necessary.

3.

Check hub fit of inner and outer ramps. Replace ramps if
excessively worn.

4.

Assemble inner and outer ramps.

a.

Apply a light coat of multi-purpose grease to balls and
ramps.

b.

Insert balls in sockets of outer ramp.

c.

Install inner ramp on hub of outer ramp with tang on
inner ramp 180 degrees from hook of outer ramp.

d.

Install

new

retaining ring (4) in groove of outer ramp

hub.

5.

Install clutch release ramp.

a.

Fit adapter (5) over clutch cable end with the rounded
side inboard, the ramp connector button outboard.

b.

With retaining ring side of ramp assembly facing
inward, place hook of ramp around coupling button.

c.

Rotate assembly counterclockwise until tang on inner
ramp fits in slot of primary cover.

HOME

2013 Sportster Service: Drive/Transmission 5-5