Harley Davidson 2013 Sportster Models. Service Manual — page 2
2.26 FRONT ENGINE MOUNT/ISOLATOR
2.27 REAR ENGINE MOUNT/ISOLATOR
2.28 THROTTLE CABLES: ALL MODELS
Removal and Disassembly. . . . . . . . . . . .2-129
Assembly and Installation. . . . . . . . . . . ...2-132
Removal. . . . . . . . . . . . . . . . . . ..2-134
Installation. . . . . . . . . . . . . . . . . ...2-135
Left Hand Grip. . . . . . . . . . . . . . . . 2-137
Removal. . . . . . . . . . . . . . . . ..2-137
Installation. . . . . . . . . . . . . . . ...2-137
All Models. . . . . . . . . . . . . . . . . ...2-138
2.32 FRONT LICENSE PLATE: INDIA
MODELS
Front License Plate: XL Models (India). . . . . . ..2-140
XL 883L/N/R. . . . . . . . . . . . . . . 2-140
XL 1200X/C/C ANV. . . . . . . . . . . . .2-140
2.33 REAR FENDER: ALL XL MODELS
EXCEPT XL 883N, XL 1200X/V
XL 883R/L. . . . . . . . . . . . . . . . . ...2-141
Removal. . . . . . . . . . . . . . . . ..2-141
Installation. . . . . . . . . . . . . . . ...2-142
XL 1200C/C ANV/CP/CA/CB. . . . . . . . . . ..2-143
Removal. . . . . . . . . . . . . . . . ..2-143
Installation. . . . . . . . . . . . . . . ...2-144
Fender Preparation. . . . . . . . . . . . . . .2-144
Tail Lamp Assembly. . . . . . . . . . . . 2-144
License Plate Bracket: XL 883R/L. . . . . . . . ..2-145
Removal. . . . . . . . . . . . . . . . ..2-145
Installation. . . . . . . . . . . . . . . ...2-145
License Plate Bracket: XL 1200C/C ANV/CP/CA/CB. .2-146
2.34 REAR FENDER AND LICENSE PLATE
BRACKET: XL 883N, XL 1200X/V
2.36 SAREE GUARD: INDIA MODELS
Saree Guard: XL 883R, XL 1200C/C ANV (India). . ..2-153
Right, Left-Rear. . . . . . . . . . . . . ...2-153
Left-Front. . . . . . . . . . . . . . . . .2-153
2.37 REAR LICENSE PLATE: INDIA MODELS
Rear License Plate: XL Models (India). . . . . . ...2-155
XL 883L/R, XL 1200C/C ANV. . . . . . . . .2-155
XL 883N, XL 1200X. . . . . . . . . . . . .2-155
Seat: XL Models. . . . . . . . . . . . . . . .2-158
Removal. . . . . . . . . . . . . . . . ..2-158
Installation. . . . . . . . . . . . . . . ...2-158
Seat: XR 1200X. . . . . . . . . . . . . . . ..2-159
Removal. . . . . . . . . . . . . . . . ..2-159
Installation. . . . . . . . . . . . . . . ...2-159
Passenger Pillion: XR 1200X. . . . . . . . . . .2-160
Removal. . . . . . . . . . . . . . . . ..2-160
Installation. . . . . . . . . . . . . . . ...2-160
2.40 RIDER FOOT CONTROLS: XL
MID-MOUNT CONTROLS
Right Footrest and Rear Brake Pedal Assembly. . . 2-161
Removal. . . . . . . . . . . . . . . . ..2-161
Installation. . . . . . . . . . . . . . . ...2-161
Left Footrest and Shift Lever Assembly. . . . . . ..2-162
Removal. . . . . . . . . . . . . . . . ..2-162
Installation. . . . . . . . . . . . . . . ...2-162
2.41 RIDER FOOT CONTROLS: XL
FORWARD CONTROLS
Right Footrest and Rear Brake Pedal Assembly. . . 2-163
Removal. . . . . . . . . . . . . . . . ..2-163
TABLE OF CONTENTS VII
TABLE OF CONTENTS
Installation. . . . . . . . . . . . . . . ...2-163
Left Footrest and Shift Lever Assembly. . . . . . ..2-164
Removal. . . . . . . . . . . . . . . . ..2-164
Installation. . . . . . . . . . . . . . . ...2-164
Adjusting Shift Pedal: Forward Controls Models. . . 2-165
2.42 RIDER FOOT CONTROLS: XR 1200X
Right Footrest and Rear Brake Pedal Assembly. . . 2-166
Removal. . . . . . . . . . . . . . . . ..2-166
Installation. . . . . . . . . . . . . . . ...2-166
Left Footrest and Shift Lever Assembly. . . . . . ..2-167
Removal. . . . . . . . . . . . . . . . ..2-167
Installation. . . . . . . . . . . . . . . ...2-167
Adjusting Shift Lever. . . . . . . . . . . . . ...2-168
XL Models. . . . . . . . . . . . . . . . . ...2-169
Removal. . . . . . . . . . . . . . . . ..2-169
Installation. . . . . . . . . . . . . . . ...2-169
XR 1200X. . . . . . . . . . . . . . . . . ...2-170
Removal. . . . . . . . . . . . . . . . ..2-170
Installation. . . . . . . . . . . . . . . ...2-170
2.45 MEDALLIONS, SERIALIZED BADGES
AND TANK EMBLEMS
ENGINE
Fastener Torque Values in this Chapter. . . . . . . ..3-1
Specifications: Sportster Models. . . . . . . . . . 3-5
Operation. . . . . . . . . . . . . . . . . . ..3-10
Checking Oil Pressure. . . . . . . . . . . . . ..3-11
3.4 CRANKCASE BREATHING SYSTEM
XL Models. . . . . . . . . . . . . . . . . . .3-13
XR 1200X. . . . . . . . . . . . . . . . . . .3-13
Diagnosing Valve Train Noise. . . . . . . . . . ...3-14
Adjustment and Testing. . . . . . . . . . . . . 3-15
General. . . . . . . . . . . . . . . . . ..3-15
3.10 REMOVING ENGINE FROM CHASSIS
3.11 INSTALLING ENGINE IN CHASSIS
3.12 PRECISION COOLING SYSTEM: XR
1200X
Removal. . . . . . . . . . . . . . . . . 3-44
Installation. . . . . . . . . . . . . . . . .3-45
Cylinder Head Oil Return Lines. . . . . . . . . . 3-45
Removal. . . . . . . . . . . . . . . . . 3-45
Installation. . . . . . . . . . . . . . . . .3-45
Cylinder Head Oil Feed Assembly. . . . . . . . . 3-46
Removal. . . . . . . . . . . . . . . . . 3-46
Installation. . . . . . . . . . . . . . . . .3-46
Oil Pump Lines. . . . . . . . . . . . . . . . .3-47
Removal. . . . . . . . . . . . . . . . . 3-47
Installation. . . . . . . . . . . . . . . . .3-48
Oil Cooler. . . . . . . . . . . . . . . . . . ..3-48
Removal. . . . . . . . . . . . . . . . . 3-48
Installation. . . . . . . . . . . . . . . . .3-48
3.13 TOP END OVERHAUL: DISASSEMBLY
Cylinder and Piston. . . . . . . . . . . . . . ...3-54
VIII TABLE OF CONTENTS
TABLE OF CONTENTS
Removal. . . . . . . . . . . . . . . . . 3-60
Installation. . . . . . . . . . . . . . . . .3-62
Refacing Valve Seats. . . . . . . . . . . . . . 3-64
Replacing Valve Seats. . . . . . . . . . . ...3-66
Assembly. . . . . . . . . . . . . . . . . . ..3-66
Cleaning, Inspection and Repair. . . . . . . . . ..3-68
Connecting Rod Bushings. . . . . . . . . . . . 3-72
3.16 TOP END OVERHAUL: ASSEMBLY
Assembling Motorcycle After Top End Repair. . . . ..3-83
3.17 BOTTOM END OVERHAUL:
DISASSEMBLY
Bushing Inspection and Removal: XL Only. . . . . ..3-89
Bushing Installation: XL Only. . . . . . . . . . . 3-89
Bushing Reaming: XL Only. . . . . . . . . . . ..3-90
Lapping Engine Main Bearing Races. . . . . . . ...3-98
3.22 BOTTOM END OVERHAUL: ASSEMBLY
Crankcase. . . . . . . . . . . . . . . . . ...3-108
TABLE OF CONTENTS IX
TABLE OF CONTENTS
FUEL SYSTEM
Fastener Torque Values in this Chapter. . . . . . . ..4-1
4.2 SPECIFICATIONS: FUEL SYSTEM
Specifications. . . . . . . . . . . . . . . . . ..4-4
XL Models except XL 1200V. . . . . . . . . . . ..4-5
Removal. . . . . . . . . . . . . . . . . ..4-5
Installation. . . . . . . . . . . . . . . . ...4-5
XL 1200V. . . . . . . . . . . . . . . . . . . 4-5
Removal. . . . . . . . . . . . . . . . . ..4-5
Installation. . . . . . . . . . . . . . . . ...4-6
XR 1200X. . . . . . . . . . . . . . . . . . ...4-6
Removal. . . . . . . . . . . . . . . . . ..4-6
Installation. . . . . . . . . . . . . . . . ...4-6
4.6 THROTTLE POSITION SENSOR (TPS)
4.7 ENGINE TEMPERATURE (ET) SENSOR
4.8 INDUCTION MODULE: XL MODELS
4.9 INDUCTION MODULE: XR 1200X
Removal. . . . . . . . . . . . . . . . . . . 4-29
Disassembly. . . . . . . . . . . . . . . . . .4-30
4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR
4.13 EXHAUST SYSTEM: XL MODELS
General. . . . . . . . . . . . . . . . . . . .4-42
Removal. . . . . . . . . . . . . . . . . . . 4-43
Installation. . . . . . . . . . . . . . . . . . .4-44
General. . . . . . . . . . . . . . . . . . . .4-46
Removal. . . . . . . . . . . . . . . . . . . 4-46
Mufflers. . . . . . . . . . . . . . . . . ..4-46
Header Pipes. . . . . . . . . . . . . . . .4-47
Installation. . . . . . . . . . . . . . . . . . .4-47
Assembly. . . . . . . . . . . . . . . . . . ..4-54
Installation. . . . . . . . . . . . . . . . . . .4-55
X TABLE OF CONTENTS
TABLE OF CONTENTS
REMOVAL
1.
Remove front brake caliper(s). See
2.
Remove front wheel assembly. See
3.
Remove front fender mounting screws and locknuts.
Remove fender. See
4.
See
. Loosen, but do not remove, slider tube
caps (1).
5.
Loosen front fork upper and lower bracket pinch screws
(2 and 3). Remove fork assemblies from fork brackets.
2
3
1
sm07586a
1. Slider tube cap
2. Upper pinch bolt
3. Lower pinch bolt
Figure 2-139. Fork Tube Bracket
DISASSEMBLY
Drain Fork Oil
1.
See
. Remove tube cap (7) from slider tube
(9). Remove O-ring (6) from tube cap.
2.
Place a pan under the fork. Remove the drain screw and
washer (19) from slider. Drain the fork oil.
Fork Disassembly
1.
See
. Remove spring (5) from slider tube.
2.
All except XL 883L and XL 1200X:
Remove spring collar
(20) and spring washer (21) from slider tube.
3.
All except XL 883N:
Remove cover (11).
NOTE
See
. The XL 883N is equipped with fork gaiters
(2) instead of metal covers. The lower lip (3) of the gaiter fits
into the groove at the upper end of the slider (1). The upper
end of the gaiter fits tightly around the slider tube, just below
the lower bracket (4).
4.
XL 883N:
See
. Peel back lower lip (3) of fork
gaiter (2) from slider groove and slide fork gaiter up and
off end of slider tube.
5.
See
. Remove dust seal (12). Compress
internal circle clip (13). Remove clip from groove in top of
slider bore.
6.
Remove screw (18) and washer (17) from bottom of slider.
NOTE
Since there is little resistance to damper tube (3) rotation within
slider tube (9) when removing screw (18), use an air impact
wrench for best results.
7.
Withdraw slider tube (9) from slider until lower bushing
(10) on slider tube contacts upper bushing (1) in slider.
8.
Tap out the oil seal (14), the spacer (2) and the upper
bushing with the lower bushing on the slider.
9.
Remove sleeve (15). Sleeve will be found within slider or
on bottom end of damper tube (3).
10. Insert a small diameter rod through opening in bottom of
slider tube to remove damper tube assembly.
11. Remove rebound spring (8) from damper tube.
12. Remove damper tube ring(s) (4) from damper tube.
13. Remove lower bushing from damper tube only if replace-
ment is necessary.
CLEANING, INSPECTION AND REPAIR
1.
Thoroughly clean and inspect all parts. Replace as
necessary.
2.
See
. Inspect the O-ring (6) for damage, wear
or general deterioration. Replace as necessary.
3.
Replace all other removed seals.
4.
Inspect damper tube ring(s) (4). Replace as necessary.
5.
Check dust seal (12) where it contacts slider tube (9). Dust
seal should provide continuous contact against slider tube
and should not show excessive wear.
6.
Check slider tube where it is contacted by seal. Tube
surface should be shiny, smooth and free of scoring or
abrasions.
7.
Verify small hole in lower end of slider tube groove is
unobstructed.
2013 Sportster Service: Chassis 2-99
6
7
5
20
21
17
8
19
3
13
11
4
25
18
22
2
15
14
1
12
24
23
26
27
28
10
16
9
sm06850a
15.
1.
Sleeve
Upper bushing
2.
16.
Spacer
Pinch bolt
17.
3.
Washer
Damper tube
4.
18.
Damper tube ring
Screw
19.
5.
Drain screw and washer (XL 883N/R)
Spring
6.
20.
O-ring
Spring collar (all except XL 883L and XL 1200X)
21.
7.
Spring washer (all except XL 883L and XL 1200X)
Tube cap
8.
22.
Rebound spring
Fork gaiter (XL 883N)
23.
9.
Washer
Slider tube
10.
24.
Lower bushing
Lockwasher
25.
11.
Nut
Cover (all except XL 883N)
12.
26.
Dust seal
Sliders (RH and LH XL 883L/N and 1200V/C/C
ANV/CP/CA/CB)
13. Internal circle clip
27.
14.
Sliders (RH and LH XL 883R)
Oil seal
28. Sliders (RH and LH XL 1200X)
Figure 2-140. Front Slider Tube/Slider Assembly: XL Models
2-100 2013 Sportster Service: Chassis
ASSEMBLY
TOOL NAME
PART NUMBER
FORK SEAL AND BUSHING
INSTALLATION TOOL
HD-36583
TORQUE VALUE
FASTENER
14.9-24.4 Nm
132-216
in-lbs
Fork slider tube fastener: XL
Models
1.
See
. If lower bushing (10) was removed,
install
new
lower bushing in groove of slider tube (9).
Expand bushing only enough to fit over tube.
2.
Install damper tube ring(s) (4) into groove(s) of damper
tube (3).
3.
Place rebound spring (8) over damper tube (3). Insert
damper tube into slider tube.
4.
Insert spring (5) into slider tube with the tapered end down.
Push damper tube through opening at bottom of slider
tube using spring. Place sleeve (15) over end of damper
tube.
5.
All except XL 1200X:
Install spring washer (21) and spring
collar (20) into slider tube.
6.
Install slider tube assembly into slider. Install screw (18)
with washer (17) at bottom of slider. Move slider tube
through its full range of travel within slider several times
to verify proper component alignment. Then, applying
downward force on spring, final tighten screw to 132-216
in-lbs
(14.9-24.4 Nm).
NOTES
•
See
. Coat the lips (3) of the oil with HARLEY-
DAVIDSON SEAL GREASE.
•
Apply HARLEY-DAVIDSON SEAL GREASE to the mating
surfaces of the dust cover and the oil seal.
7.
See
. Place upper bushing (1), spacer (2)
(concave side down) and oil seal (14) (lettering side up)
over slider tube. Place FORK SEAL AND BUSHING
INSTALLATION TOOL (Part No. HD-36583) over slider
tube. Install bushing, spacer and seal into slider bore by
tapping components downward with the installation tool.
8.
Install internal circle clip (13) into groove in top of slider
bore.
9.
Install dust seal (12) at top of slider.
10.
All except XL 883N:
Install cover (11).
11.
XL 883N:
See
. Slide a fork gaiter (2) down
each slider tube. Peel back the lower lip (3) and slip over
the end of fork slider (1). Fit the lower lip down over groove
in upper end of fork slider. Slide the upper end of fork
gaiter down as far as possible.
12.
All
except
XL
883L
and
XL
1200X/V/C/C
ANV/CP/CA/CB:
See
. Install the drain screw
and washer (19) into lower end of slider.
13. Fill the fork tube with fork oil. See
1
2
3
sm07599
1. Air side
2. Oil side
3. Lips
Figure 2-141. Oil Seal
FILL WITH FORK OIL
TOOL NAME
PART NUMBER
OIL LEVEL GAUGE
HD-59000-B
1.
Position fork tube assembly upright. Compress the
assembly fully.
2.
Pour approximately 14 fl oz (414 mL) of TYPE "E"
HYDRAULIC FORK OIL into fork.
3.
Pump the slider tube 8-10 times to expel air and compress
the assembly fully.
4.
See
. Use the OIL LEVEL GAUGE (Part
No. HD-59000-B) to set the fork oil level.
a.
Adjust the length of the draw off tube to specification
(1). Refer to
.
b.
Lock the tube (2) to the collar (3) with the thumb lock
(4).
c.
Fit the collar to the fork tube.
d.
Draw off the excess oil.
5.
Install spring and other components.
NOTE
Apply HARLEY-DAVIDSON SEAL GREASE to the O-ring.
6.
Install slider tube cap with O-ring. Screw tube cap all the
way into slider tube. Finger-tighten only.
2013 Sportster Service: Chassis 2-101
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