Harley Davidson 2013 Sportster Models. Service Manual — page 9
5
4
1
3
2
sm01421
1. Front brake master cylinder assembly
2. Diaphragm
3. Diaphragm plate
4. Reservoir cover
5. Captive screw (2)
Figure 1-42. Front Brake Master Cylinder Cover Assembly
(typical)
NOTES
•
See
. Verify that the pad spring is installed
before installing the new pads.
•
Front and rear brake caliper pads are not interchangeable.
sm01428
Figure 1-43. Front Caliper Pad Spring
5.
See
. Remove pad pin plug (3).
6.
See
. Loosen, but do not remove, brake pad
pin.
NOTE
Do not completely remove brake pad pin from caliper during
the next step. Completely removing pad pin at this time may
cause difficulty during assembly.
7.
Once the pistons have been fully retracted into their bores,
pull pad pin part way until inside pad drops free. Note the
pad's original orientation for replacement purposes.
2
1
3
4
sm01429
1. Front brake caliper
2. Caliper mounting bracket
3. Pad pin plug
4. Caliper mounting pins
Figure 1-44. Front Caliper Assembly
sm01430
Figure 1-45. Brake Pad Pin (plug removed)
8.
See
. Install
new
inside brake pad (1) using
same orientation as pad previously removed. Align
mounting tabs.
9.
While holding
new
inside pad in place, pull pad pin out
and remove outside brake pad. Note the pad's original
orientation for replacement purposes.
10. Install
new
outside brake pad using the same orientation
as pad previously removed. Align mounting tabs.
11. Temporarily insert a 1/8 drill bit in caliper pad pin hole to
hold both pads in place.
12. Inspect pad pin for grooving and wear. Measure pad pin
diameter in an unworn area, and then in the area of any
1-42 2013 Sportster Service: Maintenance
grooving or wear. If wear exceeds 0.011 in (0.28 mm),
replace pin.
3
1
1
3
2
2
4
5
sm01431
1. Brake pad
2. Front mounting tab
3. Pad pin hole
4. Front caliper mounting bracket
5. Slot
Figure 1-46. Front Brake Pads
13. Press brake pads firmly up against pad spring. Remove
drill bit. Install pad pin. Tighten to 131-173
in-lbs
(14.8-
19.6 Nm).
NOTE
If pad pin does not fit, check the following:
•
You are using a set of pads, not two identical pads.
•
Pad spring orientation must match
•
See
. Fully seat mounting tabs (2) in slot (5).
•
Push pads against pad spring before installing pad pin.
14. See
. Install pad pin plug (3). Tighten to 18-25
in-lbs
(2.0-2.9 Nm).
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
15. Pump brake lever to move pistons out until they contact
outside brake pad. Verify piston location against pad.
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTE
If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY
flush area with clear water.
16. See
. Check brake fluid level in master cylinder.
Add enough DOT 4 BRAKE FLUID to reservoir to bring
fluid level even with ridge (1) cast into inside of reservoir,
about 1/4 in (6.35 mm) below top edge.
1
2
sm01422
1. Cast-in ridge
2. Sight glass
Figure 1-47. Filling Front Master Cylinder Reservoir
(typical)
17. See
. Install diaphragm (2), diaphragm plate
(3), reservoir cover (4) and screws (5) on front brake
master cylinder reservoir. Tighten screws to 9-17
in-lbs
(1.0-2.0 Nm).
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)
2013 Sportster Service: Maintenance 1-43
18. Test brake system.
a.
Turn ignition switch ON. Pump brake lever to verify
operation of the stop lamp.
b.
Test ride the motorcycle. If the brakes feel spongy,
bleed the system. See
.
NOTE
Avoid making hard stops for the first 100 mi (160 km). This
allows the new pads to become conditioned to the brake discs.
BRAKE PAD REPLACEMENT: REAR
TORQUE VALUE
FASTENER
14.8-19.6 Nm
131-173
in-lbs
Brake pad pin
2.0-2.9 Nm
18-25
in-lbs
Brake pad pin plug
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTES
•
See
. Do not remove or loosen the caliper
mounting pins (4). Removing caliper from mounting bracket
increases the risk of contaminants falling into caliper boots
and bushings. These contaminants could damage caliper
during vehicle operation.
•
If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.
1.
Position vehicle on a flat level surface.
NOTE
See
. As the piston is pushed back into the caliper,
fluid level may rise higher than the upper fluid level (3) in the
reservoir (1). You may have to remove fluid to allow for this.
2.
See
. Remove rear master cylinder reservoir
cap (2).
3.
Place a suitable container under the rear master cylinder
to catch any fluid that may overflow.
2
4
3
5
2
1
4
3
sm01425
1. Rear brake master cylinder reservoir
2. Reservoir cap
3. Upper fluid level
4. Lower fluid level
5. Reservoir cover
Figure 1-48. Rear Brake Master Cylinder Reservoir: XL
Models
4.
Press against the side of the brake caliper body to push
the outside brake pad (pad closest to caliper piston) back.
This pushes the caliper piston back into its bore.
NOTES
•
See
. Verify that the pad spring is installed
before installing new pads.
•
Front and rear brake pads are not interchangeable.
1-44 2013 Sportster Service: Maintenance
sm01432
Figure 1-49. Rear Caliper Pad Spring
5.
See
. Remove pad pin plug (3).
6.
See
. Loosen, but do not remove, brake pad
pin.
NOTE
Do not completely remove brake pad pin from caliper during
the next step. Completely removing pad pin at this time may
cause difficulty during assembly.
7.
Once the piston has been fully retracted into its bore, pull
pad pin part way until inside pad drops free. Note the pad's
original orientation for replacement purposes.
4
3
2
1
sm03590a
1. Rear brake caliper
2. Caliper mounting bracket
3. Pad pin plug
4. Caliper mounting pins
Figure 1-50. Rear Caliper Assembly
sm01434
Figure 1-51. Brake Pad Pin (plug removed)
8.
See
. Install
new
inside brake pad (2) using
same orientation as pad previously removed. Align
mounting tabs.
9.
While holding
new
inside pad in place, pull pad pin out
and remove outside brake pad (1). Note the pad's original
orientation for replacement purposes.
10. Install
new
outside brake pad using the same orientation
as pad previously removed. Align mounting tabs.
11. Temporarily insert a 1/8-in (3.175 mm) drill bit in caliper
pad pin hole to hold pads in place.
12. Inspect pad pin for grooving and wear. Measure pad pin
diameter in an unworn area, and then in the area of any
grooving or wear. If wear exceeds 0.011 in (0.28 mm),
replace pin.
13. Press brake pads firmly up against pad spring. Remove
drill bit. Install pad pin. Tighten to 131-173
in-lbs
(14.8-
19.6 Nm).
2013 Sportster Service: Maintenance 1-45
NOTE
If pad pin does not fit, check the following:
•
You are using a set of pads, not two identical pads.
•
Pad spring orientation must match
•
See
. Pad front mounting tabs (3) must be fully
seated in mounting bracket slot (6).
•
Before the pad pin is installed, push pads up against the
pad spring.
14. See
. Install pad pin plug (3). Tighten to 18-25
in-lbs
(2.0-2.9 Nm).
3
4
1
2
4
5
6
sm01435a
1. Outside brake pad
2. Inside brake pad
3. Front mounting tab
4. Pad pin hole
5. Rear caliper mounting bracket
6. Slot
Figure 1-52. Rear Brake Pads
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
15. Pump brake pedal to move piston out until it contacts
outside brake pad. Verify piston location against pad.
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTES
•
If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.
•
Fill the rear brake master cylinder reservoir must be in a
level position.
•
See
. Reservoir cover (5) may be removed
from rear brake master cylinder reservoir (1) to more easily
verify fluid level in reservoir.
16. See
. If desired, remove rear brake master
cylinder reservoir cover (5) by grasping cover and gently
pulling it straight away from reservoir (1).
17. Check brake fluid level in master cylinder reservoir. If
necessary, add DOT 4 BRAKE FLUID to reservoir until
fluid reaches upper fluid level (3).
18. Replace master cylinder reservoir cap (2). Replace
reservoir cover (5), if removed.
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)
19. Test brake system.
a.
Turn ignition switch ON. Pump brake pedal to verify
operation of the stop lamp.
b.
Test ride motorcycle at low speed. If the brakes feel
spongy, bleed the system. See
.
NOTE
Avoid making hard stops for the first 100 mi (160 km). This
allows the new pads to become conditioned to the brake discs.
1-46 2013 Sportster Service: Maintenance
1.17
BRAKE PADS AND DISCS: XR 1200X
INSPECTION
Brake Pads
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
See
. Replace brake pads if thickness of brake pad
friction material (3) is worn to 0.040 in (1.02 mm) or less.
Always replace both pads in a caliper as a set. See
1.17 BRAKE PADS AND DISCS: XR 1200X, Brake Pad
Replacement: Front
or
1200X, Brake Pad Replacement: Rear
When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage or leakage.
Brake Disc Thickness, Lateral Runout and
Warpage
See
. The minimum brake disc (4) thickness is
stamped on the side of the disc. Replace disc if worn past
minimum thickness or badly scored.
Maximum brake disc lateral runout and warpage is 0.008 in
(0.2 mm) when measured near the outside diameter.
•
To replace front brake disc(s), see
•
To replace rear brake disc, see
1
3
2
sm07225
1. Front, from below
2. Rear, from above
3. MIN thickness
Figure 1-53. Brake Pad MIN Thickness: XR 1200X
4
3
2
1
sm05127
1. Friction material thickness
2. Pad backing plate
3. Friction material
4. Brake disc
Figure 1-54. Brake Pad Inspection (front brake shown)
2013 Sportster Service: Maintenance 1-47
BRAKE PAD REPLACEMENT: FRONT
TORQUE VALUE
FASTENER
14.8-19.6 Nm
131-173
in-lbs
Brake pad pin
1.0-2.0 Nm
9-17
in-lbs
Brake master cylinder, front,
reservoir cover screws
Removal
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTES
•
If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.
•
Cover handlebar switches with a shop towel before adding
brake fluid to front master cylinder reservoir. Spilling brake
fluid on handlebar switches may render them inoperative.
1.
Turn handlebar to level the front master cylinder reservoir.
2.
See
. Remove two screws (5), reservoir cover
(4), diaphragm plate (3) and diaphragm (2) from master
cylinder reservoir (1).
NOTE
As the pistons are pushed back into the caliper, fluid level may
rise higher than fluid level mark at about 1/4 in (6.35 mm) below
top of reservoir. Remove fluid as necessary to prevent overflow.
3.
Wrap a shop towel around the master cylinder reservoir
to contain any brake fluid spills.
4.
Pry between the brake pads and brake disc to force all
caliper pistons back into their bores. Do not to scratch the
rotor or cause warpage.
5
4
1
3
2
sm01421
1. Front brake master cylinder assembly
2. Diaphragm
3. Diaphragm plate
4. Reservoir cover
5. Captive screw (2)
Figure 1-55. Front Brake Master Cylinder Cover Assembly
(typical)
5.
See
. Remove pad pins (1).
6.
Remove pad spring (2) and brake pads through opening
in caliper assembly.
NOTE
The pad pins are manufactured with a relief near the center of
their length, where the pad spring touches. Do not use this
area as a measurement point to determine pad pin wear.
7.
Inspect pad pin for grooving and wear. Measure pad pin
diameter in an unworn area and in the area of any grooving
or wear. If wear exceeds 0.011 in (0.28 mm), replace pin.
8.
Inspect pad spring for wear or cracks. Replace if neces-
sary.
1-48 2013 Sportster Service: Maintenance
2
1
1
sm05128b
1. Pad pins
2. Pad spring
Figure 1-56. Front Caliper Assembly: XR 1200X
Installation
NOTE
See
. When replacing front brake pads, make sure
pad spring is installed with the arrow and word UP (2) pointing
up and captured by both pad pins (3).
1.
See
. Install
new
outer brake pad and pad
spring. Make sure friction material faces brake disc.
NOTE
If pad pin does not fit, check the following:
•
You are using the correct set of pads.
•
Pad spring orientation must match
•
Push pads tight up against pad spring before pad pins are
installed.
2.
While holding
new
outer pad in place, insert pad pins
through holes in tabs of pad and into pad spring.
3.
Install
new
inner brake pad, making sure friction material
faces brake disc.
4.
Push pad pins through holes in tabs of inner pad and into
holes in caliper housing.
5.
Tighten pad pins to 131-173
in-lbs
(14.8-19.6 Nm).
1
3
2
sm05101
1. Banjo bolt hole
2. Arrow and word "UP"
3. Pad pins (2)
Figure 1-57. Front Caliper Pad Spring Orientation
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
6.
Pump brake lever to move pistons out until they contact
outside brake pad. Verify piston location against pad.
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTE
If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY
flush area with clear water.
7.
See
. Check brake fluid level in master cylinder.
Add enough DOT 4 BRAKE FLUID to reservoir to bring
fluid level even with ridge (1) cast into inside of reservoir,
about 1/4 in (6.35 mm) below top edge.
2013 Sportster Service: Maintenance 1-49
1
2
sm01422
1. Cast-in ridge
2. Sight glass
Figure 1-58. Filling Front Master Cylinder Reservoir
(typical)
8.
See
. Install diaphragm (2), diaphragm plate
(3), reservoir cover (4) and screws (5) on front brake
master cylinder reservoir. Tighten screws to 9-17
in-lbs
(1.0-2.0 Nm).
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)
9.
Test brake system.
a.
Turn ignition switch ON. Pump brake lever to verify
operation of the stop lamp.
b.
Test ride the motorcycle at low speed. If the brakes
feel spongy, bleed the system. See
.
NOTE
Avoid making hard stops for the first 100 mi (160 km). This
allows the new pads to become conditioned to the brake discs.
BRAKE PAD REPLACEMENT: REAR
TORQUE VALUE
FASTENER
14.8-19.6 Nm
131-173
in-lbs
Brake pad pin
2.0-2.9 Nm
18-25
in-lbs
Brake pad pin plug
Removal
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTES
•
Do not remove rear caliper from mounting bracket unless
caliper mounting pins and boots require service. Removing
caliper from mounting bracket unnecessarily increases
the risk of contaminants falling into caliper boots and
bushings. These contaminants could damage caliper
during vehicle operation.
•
See
. It is not required or recommended to
remove or loosen the caliper mounting fasteners (2).
•
It is not necessary or recommended to remove the rear
brake caliper from the caliper mounting bracket to replace
pads.
•
If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.
1.
Place motorcycle in an upright, level position.
2.
Remove rear master cylinder reservoir cover.
3.
Place a suitable container under the rear master cylinder
to catch any fluid that may overflow.
NOTE
The fluid level can rise above the upper fluid level in the
reservoir. Remove fluid as necessary.
4.
Press against the outside of the brake caliper body to push
the caliper piston back into its bore, forcing fluid back to
the reservoir.
NOTE
See
. Verify that pad spring is installed before
installing new pads.
sm05122
Figure 1-59. Rear Caliper Pad Spring
NOTE
Left shock absorber is disconnected from rear fork for clarity
of photograph. Pad replacement does not require the shock
be disconnected.
5.
See
. Remove pad pin plug (1).
6.
Loosen, but do not remove, brake pad pin (metric).
7.
Pull pad pin part way out until inner pad drops free.
Remove pad and note the pad's original orientation for
replacement purposes.
8.
Continue to remove pad pin until outer pad drops free.
1-50 2013 Sportster Service: Maintenance
9.
Inspect pad pin for grooving and wear.
10. Measure pad pin diameter in an unworn area and then in
the area of any grooving or wear. If wear exceeds 0.011
in (0.28 mm), replace pin.
1
2
2
sm05129a
1. Pad pin plug
2. Mounting fasteners
Figure 1-60. Rear Caliper Assembly: XR 1200X
Installation
NOTE
The caliper and mounting bracket are shown removed for clarity
of photograph. Removal is not required to replace brake pads.
1.
See
. Install
new
outside brake pad using the
same orientation as pad previously removed. Make sure
front mounting tab (3) is seated in slot (6) in caliper
mounting bracket and pad friction material faces brake
disc.
2.
Install pad pin into caliper and through outer pad.
3.
Position inner pad and continue to install pad pin while
pressing brake pads firmly up against pad spring. Tighten
pad pin to 131-173
in-lbs
(14.8-19.6 Nm).
NOTE
If pad pin does not fit, check the following:
•
The part number of the pads.
•
See
. Check pad spring orientation.
•
See
. Pad front mounting tabs (3) must be fully
seated in mounting bracket slot (6).
•
Push the pads tight up against pad spring before pad pin
is installed.
4.
Install pad pin plug. Tighten to 18-25
in-lbs
(2.0-2.9 Nm).
3
4
1
2
4
5
6
sm01435a
1. Outside brake pad
2. Inside brake pad
3. Front mounting tab
4. Pad pin hole
5. Rear caliper mounting bracket
6. Slot
Figure 1-61. Rear Brake Pads: XR 1200X
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
5.
Pump brake pedal to move piston out until it contacts
outside brake pad. Verify piston location against pad.
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
NOTE
Position rear brake master cylinder reservoir level when filling
or checking fluid level
6.
Check brake fluid level in master cylinder reservoir. If
necessary, add DOT 4 BRAKE FLUID to reservoir until
fluid reaches upper fluid level.
7.
Replace reservoir cover.
2013 Sportster Service: Maintenance 1-51
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)
8.
Test brake system.
a.
Turn ignition switch ON. Pump brake pedal to verify
operation of the stop lamp.
b.
Test ride motorcycle at low speed. If the brakes feel
spongy, bleed the system. See
.
NOTE
Avoid making hard stops for the first 100 mi (160 km). This
allows the new pads to become conditioned to the brake discs.
1-52 2013 Sportster Service: Maintenance
1.18
SPARK PLUGS
REMOVAL
Disconnecting spark plug cable with engine running can
result in electric shock and death or serious injury.
(00464b)
NOTE
Allow the engine to cool before servicing.
1.
Disconnect spark plug cables.
2.
Remove spark plugs.
INSPECTION
NOTE
Discard plugs with eroded electrodes, heavy deposits or a
cracked insulator.
See
. Compare plug deposits to
.
1
2
3
4
sm00099a
Figure 1-62. Spark Plug Deposits
Table 1-16. Spark Plug Deposit Analysis
POSSIBLE CAUSE
DEPOSITS
PLUG*
Worn pistons
Worn piston rings
Worn valves
Worn valve guides
Worn valve seals
Weak battery
Faulty ignition system
Wet, black and shiny
1
Air-fuel mixture too rich
Dry, fluffy or sooty
and black
2
Air-fuel mixture too lean
Hot running engine
Valves not seating
Improper ignition timing
Light brown and
glassy**
May be accompanied
by cracks in the insu-
lator or by electrode
erosion.
3
Balanced combustion
Clean off deposits at regular
intervals.
White, gray or tan
and powdery
4
* See
** The glassy deposit on a spark plug may cause high-speed
misfiring.
CLEANING
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)
If the plugs require cleaning between tune-ups:
1.
Clean electrodes and insulator with electrical contact
cleaner. Dry plug with compressed air.
2.
Use a thin file to flatten electrodes.
NOTE
Electrodes with sharp edges require 25-40 percent less voltage
than ones with rounded edges.
3.
Check condition of threads in cylinder head. Use a penet-
rating oil and clean out with a thread chaser. Verify that
plug threads are clean.
4.
If necessary, replace with
new
spark plugs.
INSTALLATION
TORQUE VALUE
FASTENER
16.3-24.4 Nm
12-18 ft-lbs
Spark plug
1.
Verify proper gap before installing
new
or cleaned spark
plugs.
a.
Select a wire-type feeler gauge within specification.
Refer to
2013 Sportster Service: Maintenance 1-53
NOTE
The spark plug gap is within specification when there is a
slight drag on the gauge.
b.
Pass the wire gauge between the center and the outer
electrodes.
c.
If necessary use the proper tool to bend the outer
electrode to bring the gap to within specification.
2.
Apply ANTI-SEIZE LUBRICANT to the spark plug threads.
Tighten to 12-18 ft-lbs (16.3-24.4 Nm).
3.
See
. Connect spark plug cables. Verify cables
are connected to coil, spark plugs and anchor clips or
harness caddies.
sm07488
Figure 1-63. Spark Plug Cable Routing: All Models
Table 1-17. Spark Plug Gap
mm
in
TYPE
MODEL
0.97-1.09
0.038-0.043
6R12
XL
0.81-0.97
0.032-0.038
10R12X
XR
SPARK PLUG CABLE INSPECTION
1.
Inspect spark plug cables. Replace if necessary.
a.
Check for cracks or loose terminals.
b.
Check for loose fit on ignition coil and spark plugs.
2.
Check cable boots/caps for cracks or tears. Replace
boots/caps that are worn or damaged.
3.
See
. Check spark plug cable resistance with
an ohmmeter. Replace cables not meeting resistance
specifications. Refer to
Table 1-18. Spark Plug Cable Resistance
RESISTANCE (OHMS)
CABLE
1,750-4,836
Front
4,843-15,420
Rear
1
3
2
4
sm02659a
1. Ohmmeter positive lead
2. Ohmmeter negative lead
3. Spark plug cable
4. Ohmmeter
Figure 1-64. Testing Resistance
1-54 2013 Sportster Service: Maintenance
1.19
STEERING HEAD BEARINGS
FALL-AWAY
TORQUE VALUE
FASTENER
40.7-47.5 Nm
30-35 ft-lbs
Fork stem pinch bolt
40.7-47.5 Nm
30-35 ft-lbs
Fork bracket pinch screw
Measurement
1.
Raise the front wheel off the floor.
2.
Remove the components that interfere with front fork
swing.
3.
Disconnect the clutch cable.
4.
Cover the front fender tip with a strip of masking tape.
5.
Install a pointer mounted to a floor stand. With the front
wheel pointed straight ahead, position the pointer at the
center of the fender.
6.
Tap the fender on one side until the front fork begins to
pivot (fall-away) without being tapped. Mark that point.
Repeat in the opposite direction.
7.
Measure the distance between the two fall-away marks.
8.
If fall-away is not within specification, adjust the fork stem
bolt. Refer to
.
Table 1-19. Fall-Away Specifications
MAXIMUM
MINIMUM
MODEL
mm
in
mm
in
50
2.0
25
1.0
XL models
100
4.0
50
2.0
XR 1200X
Adjustment
1.
See
. Loosen the two lower bracket pinch
screws (2) and the fork stem pinch screw (1).
2.
Adjust fall-away:
a.
If fall-away is more than the maximum, loosen the
fork stem bolt (3).
b.
If fall-away is less than the minimum, tighten the fork
stem bolt.
3.
Tighten the fork stem pinch screw to 30-35 ft-lbs (40.7-
47.5 Nm) and tighten the lower bracket pinch screws to
30-35 ft-lbs (40.7-47.5 Nm).
4.
Verify fall-away.
LUBRICATION
See
. Disassemble the steering head assembly
and lubricate the tapered roller bearings with SPECIAL PUR-
POSE GREASE. See
.
3
2
1
2
sm06644a
1. Fork stem pinch screw
2. Bracket pinch screws
3. Fork stem bolt
Figure 1-65. Steering Head Assembly (typical)
2013 Sportster Service: Maintenance 1-55
1.20
CRITICAL FASTENERS
INSPECTION
Checking Torques on Fasteners
Inspect critical fasteners at the scheduled service intervals.
Replace any damaged or missing fasteners.
1.
Attempt to turn the fastener using a torque wrench set to
the minimum torque specification for that fastener. Refer
to
a.
If the fastener does not rotate, the fastener torque
has been maintained. No further attention is neces-
sary.
b.
If the fastener rotates, remove it to determine if it has
a locking agent.
c.
If it has a locking agent, clean all locking material from
the threaded hole. Replace the fastener with a
new
one or clean the original fastener threads and apply
the appropriate locking agent (see appropriate pro-
cedure).
d.
Install fastener. Tighten to specification.
2.
If the fastener does not have a locking agent, install
fastener. Tighten to specification.
Table 1-20. Critical Fasteners
TORQUE
FASTENER
SYSTEM
4.0-5.1 Nm
35-45
in-lbs
Switch housing screws, upper and lower
Hand controls
12.2-14.9 Nm
108-132
in-lbs
Clutch lever handlebar clamp screws
12.2-14.9 Nm
108-132
in-lbs
Master cylinder handlebar clamp screws
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screws
Engine
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link frame bracket mounting
screws, upper front
74.6-88.2 Nm
55-65 ft-lbs
Stabilizer link engine bracket mounting
screws, upper front
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link frame bracket mounting
screws, lower front
129-142 Nm
95-105 ft-lbs
Isolator mounting bolt, front
81.4-95.0 Nm
60-70 ft-lbs
Fork pivot/engine mount bolts
33.9-47.5 Nm
25-35 ft-lbs
Isolator mounting bracket screws, front (left
side)
33.9-47.5 Nm
25-35 ft-lbs
Isolator mounting bracket screws, rear (left
side)
27.1-33.9 Nm
20-25 ft-lbs
Brake line banjo bolts
Brakes
21.7-32.6 Nm
16-24 ft-lbs
Brake disc mounting screws, front
40.7-61.1 Nm
30-45 ft-lbs
Brake disc mounting screws, rear
1.0-2.0 Nm
9-17
in-lbs
Reservoir cover screws, front
23.1-29.9 Nm
17-22 ft-lbs
Master cylinder mounting screws, rear: XL
8.1-10.9 Nm
72-96
in-lbs
Master cylinder mounting screws, rear: XR
23.1-29.9 Nm
17-22 ft-lbs
Master cylinder bracket-to-frame mounting
screws, rear: XL
61-67.8 Nm
45-50 ft-lbs
Master cylinder/footrest bracket-to-frame
mounting screws, rear: XR
38.0-51.6 Nm
28-38 ft-lbs
Brake caliper mounting bolts, front
81-88 Nm
60-65 ft-lbs
Front
Axle nuts
129-142 Nm
95-105 ft-lbs
Rear
1-56 2013 Sportster Service: Maintenance
Table 1-20. Critical Fasteners
TORQUE
FASTENER
SYSTEM
40.7-47.5 Nm
30-35 ft-lbs
Lower bracket pinch screws
Front fork/handlebar
40.7-47.5 Nm
30-35 ft-lbs
Fork upper bracket pinch screws
31.2-36.6 Nm, loosen,
23-27 ft-lbs, loosen,
Fork stem bolt
8.1-10.9 Nm
72-96
in-lbs
40.7-47.5 Nm
30-35 ft-lbs
Fork stem pinch screw
28.5-36.6 Nm
21-27 ft-lbs
Axle pinch screw, front: XL
55.6-65.1 Nm
41-48 ft-lbs
Axle pinch screw, front: XR
16.3-24.4 Nm
12-18 ft-lbs
Handlebar clamp mounting screw
40.7-54.3 Nm
30-40 ft-lbs
Riser mounting bolts
81.3 Nm, loosen 180
degrees, 108 Nm
60 ft-lbs, loosen 180 degrees,
80 ft-lbs
Sprocket mounting bolts, rear
Final drive
2013 Sportster Service: Maintenance 1-57
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