Harley Davidson 2013 Sportster Models. Service Manual — page 19

Loose the rear axle and drive belt. See

CONTROLS: XL FORWARD CONTROLS

XL Models with Forward Mount Controls:

Remove both

forward control assemblies. See

2.41 RIDER FOOT

Support front of engine with FAT JACK (Part No. HD-
45968) and suitable blocks.

See

. Remove screw (4) securing upper front

stabilizer link (2) to stabilizer link bracket (3).

See

. Remove screw (3) securing lower front

stabilizer link (1) to stabilizer link bracket (2).

See

. Remove screw (4) from left end of rear

stabilizer link (1) and ground strap (2). Remove spacer
(5).

NOTE

See

Figure 2-170

. Jack the engine up or down to remove bolt

(3).

10. Remove nut (4) and bolt (3) from front engine mount/isol-

ator assembly.

11. Remove screws (5) from front isolator mount (2) on left

side of motorcycle. Remove isolator mount and left front
isolator (1).

12. Without damaging the wire harness caddy, raise the front

of the engine.

13. Without damaging the frame downtube, carefully pry front

end of engine to the left approximately 1.0 in (25.4 mm).

14. Remove the right front isolator (1) from the crankcase.

sm01823a

1. Isolator
2. Front isolator mount
3. Bolt
4. Nut
5. Screw (2)

Figure 2-170. Front Engine Mount/Isolator

INSTALLATION

TOOL NAME

PART NUMBER

FAT JACK

HD-45968

TORQUE VALUE

FASTENER

33.9-47.5 Nm

25-35 ft-lbs

Isolator, front, mounting
bracket screw

129-142 Nm

95-105 ft-lbs

Engine mount, front, bolt

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link, upper front,
frame bracket mounting screw

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

See

Figure 2-170

. Install both front isolators (1) in engine

mounting boss on front of crankcase. Note that each isol-
ator has a half-moon tab and fits into engine mounting
boss in only one way. Push engine to the right until right
isolator contacts frame boss.

Install front isolator mount (2) over left front isolator.

Install screws (5) through front isolator mount and thread
into frame. Tighten to 25-35 ft-lbs (33.9-47.5 Nm).

Insert bolt (3) through front isolator/engine mount assembly
from left side. Thread nut (4) onto bolt. Tighten to 95-105
ft-lbs (129-142 Nm).

See

. Attach lower front stabilizer link (1) to

bracket (2) with screw (3). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).

2-120 2013 Sportster Service: Chassis

See

. Attach upper front stabilizer link (2) to

bracket (3) with screw (4). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).

See

2.41 RIDER FOOT CONTROLS: XL

. Install screw (4) through free end of

ground strap (2), rear stabilizer link (1), spacer (5), and
into engine crankcase. Tighten to 25-35 ft-lbs (33.9-47.5
Nm).

Remove FAT JACK (Part No. HD-45968) and blocks from
under engine.

Forward Mount Controls:

Install both forward control

assemblies. See

FORWARD CONTROLS

10. Install the exhaust system. See

4.13 EXHAUST SYSTEM:

XL MODELS

4.14 EXHAUST SYSTEM: XR 1200X

11.

XR 1200X:

Install the air box assembly. See

12. Adjust the drive belt and tighten the rear axle. See

2013 Sportster Service: Chassis 2-121

2.27

REAR ENGINE MOUNT/ISOLATOR

REMOVAL

TOOL NAME

PART NUMBER

SHOP DOLLY

HD-45967

FAT JACK

HD-45968

XR 1200X:

Remove the air box assembly. See

4.14 EXHAUST SYSTEM: XR 1200X

Remove exhaust system. See

4.13 EXHAUST SYSTEM:

XL MODELS

With the aid of a FAT JACK (Part No. HD-45968), support
motorcycle on SHOP DOLLY (Part No. HD-45967).

NOTE

Position vehicle on SHOP DOLLY so that FAT JACK may be
used (with the aid of suitable blocks) to support engine when
rear engine mount is removed.

Remove sprocket cover.

XL Models:

See

Figure 2-171

. Remove screw (6),

washer (5) and exhaust pipe clamp bracket (4).
Remove two screws (2, 3). Remove sprocket cover
(1).

XR 1200X:

See

Figure 2-172

. Remove screw and

washer (2) and screws (3, 4). Remove sprocket cover
(1).

Loosen rear axle and remove rear drive belt. See

2.42 RIDER FOOT CONTROLS: XR 1200X

XL Models with Passenger Footrests:

Remove left

passenger footrest assembly. See

2.43 PASSENGER

FOOTRESTS

XR 1200X:

Remove left and right rider controls and

brackets. See

Unbolt rear brake master cylinder remote reservoir. Do
not disconnect hose from reservoir. Secure reservoir to
vehicle in an upright position, out of the way. See

2.13 REAR BRAKE MASTER CYLINDER RESERVOIR

Support rear fork assembly using vehicle tiedown straps.

10. See

EMISSIONS CONTROL, Charcoal Canister

. Remove rear fork pivot bolts (1).

11. Pull rear fork back far enough to clear rear engine mounts

and isolators.

12.

Motorcycles Equipped with EVAP:

Remove EVAP

canister and mounting bracket. See

4.20 EVAPORATIVE

13. See

. Remove screws (3, 4) securing rear

stabilizer link (1). Remove stabilizer link, ground strap (2),
and spacer (5).

14. See

. Remove screw (4) securing upper front

stabilizer link (2) to stabilizer link bracket (3).

15. See

. Remove screw (3) securing lower front

stabilizer link (1) to stabilizer link bracket (2).

16. Support rear of engine with lifting device and suitable

blocks.

17. See

. Remove two screws (7) securing rear

isolator mount (2) to left side of frame. Remove isolator
mount and left isolator (3).

18. Remove three screws (6) securing rear pivot lockplate (5)

to rear of engine case. Remove lockplate and rear fork
pivot shaft (4).

NOTE

Engine may need to be jacked up or down slightly to aid in
removing pivot shaft.

19. Carefully pry rear end of engine to the left approximately

1.0 in (25.4 mm). Remove right rear isolator (3) from frame.

sm01824

1. Sprocket cover
2. Screw
3. Screw
4. Exhaust pipe clamp bracket
5. Washer
6. Screw

Figure 2-171. Sprocket Cover: XL Models

2-122 2013 Sportster Service: Chassis

sm05328

1. Sprocket cover
2. Rear screw and washer
3. Front screw
4. Lower screw

Figure 2-172. Sprocket Cover: XR 1200X

sm01825a

1. Bolt (2)
2. Rear isolator mount
3. Isolator (2)
4. Rear fork pivot shaft
5. Rear pivot lockplate
6. Screw (3)
7. Screw (2)

Figure 2-173. Rear Engine Mount/Isolator: Typical (XL

Models)

INSTALLATION

TOOL NAME

PART NUMBER

FAT JACK

HD-45968

TORQUE VALUE

FASTENER

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and
lower screw

33.9-47.5 Nm

25-35 ft-lbs

Isolator, front, mounting
bracket screw

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link, upper front,
frame bracket mounting screw

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link, lower front,
frame bracket mounting screw

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screw

81.4-95.0 Nm

60-70 ft-lbs

Fork, lower front, pivot/engine
mount bolt

40.7-44.7 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket
screw

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and
lower screws

40.7-44.7 Nm

30-33 ft-lbs

Sprocket cover, rear screw

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and
lower screws

See

. Install

new

right rear isolator (3) into

frame, lining up tabs on isolator with slots in frame. Slide
rear end of engine to the right until engine mounting boss
on rear of crankcase contacts right isolator.

Slide rear fork pivot shaft (4) through engine mounting
boss.

NOTE

Engine may need to be moved slightly in one direction or
another to align pivot shaft with isolator.

Install rear pivot lockplate (5) over pivot shaft with ridges
on lockplate engaging flats on pivot shaft flange. Secure
to crankcase with three screws (6). Tighten to 80-120

in-lbs

(9.0-13.6 Nm).

Install

new

left rear isolator (3) on rear fork pivot shaft.

Place rear isolator mount (2) over left rear isolator, lining
up tabs on isolator with slots in isolator mount. Install
screws (7). Tighten to 25-35 ft-lbs (33.9-47.5 Nm).

Remove FAT JACK (Part No. HD-45968) and blocks.

See

. Attach upper front stabilizer link (2) to

bracket (3) with screw (4). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).

See

. Attach lower front stabilizer link (1) to

bracket (2) with screw (3). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).

See

. Install ground strap (2) and rear stabil-

izer link (1) to right side frame using short screw (3). Install
free end of ground strap, stabilizer link and spacer (5) into
engine case using long screw (4). Tighten screws to 25-
35 ft-lbs (33.9-47.5 Nm).

SIONS CONTROL, Charcoal Canister

2013 Sportster Service: Chassis 2-123

NOTE

XR 1200X: Check that the ground strap does not contact the
rear stop switch harness before tightening stabilizer link screws.

10.

Motorcycles Equipped with EVAP:

Install EVAP canister

and mounting bracket. See

4.20 EVAPORATIVE EMIS-

11. See

2.13 REAR BRAKE MASTER CYLINDER RESERVOIR

. Slide rear fork forward into position.

Install rear fork pivot/engine mount bolts (1). Tighten to
60-70 ft-lbs (81.4-95.0 Nm). Remove vehicle tiedown
straps supporting rear fork.

12. Install rear brake master cylinder remote reservoir. See

13.

XL Models equipped with Passenger Footrests:

Install

left passenger footrest assembly. See

2.43 PASSENGER

FOOTRESTS

14.

XR 1200X:

Install left and right rider foot controls and

brackets. See

2.42 RIDER FOOT CONTROLS: XR 1200X

15. Install and adjust rear drive belt and tighten rear axle. See

4.14 EXHAUST SYSTEM: XR 1200X

16.

XL Models:

Install sprocket cover.

See

Figure 2-171

. Install sprocket cover (1). Secure

with two screws (2, 3). Note that long screw goes in
top hole, short screw in bottom hole. Do not tighten
screws at this time.

Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.7 Nm). Now
tighten screws (2, 3) to 80-120

in-lbs

(9.0-13.6 Nm).

17.

XR 1200X:

Install sprocket cover.

See

Figure 2-172

. Tighten screw (2) to 30-33 ft-lbs

(40.7-44.7 Nm).

Tighten screws (3, 4) to 80-120

in-lbs

(9.0-13.6 Nm).

18. Install exhaust system. See

4.13 EXHAUST SYSTEM: XL

MODELS

19.

XR 1200X:

Install the air box assembly. See

2-124 2013 Sportster Service: Chassis

2.28

THROTTLE CABLES: ALL MODELS

REMOVAL AND DISASSEMBLY

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)

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.4 FUEL TANK: XL MODELS

4.5 FUEL TANK: XR

1200X

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

Remove seat.

Remove fuel tank. See

4.4 FUEL TANK: XL MODELS

4.5 FUEL TANK: XR 1200X

XL Models:

See

Figure 2-174

. Remove screw (3) securing left

wire harness caddy (2) to right wire harness caddy
(1). See

6.28 ELECTRICAL CADDIES

. Separate left

wire harness caddy from right wire harness caddy.

Cut cable straps (5) securing throttle cables (4) to
right wire harness caddy. Remove and discard cable
straps.

Disengage ignition coil bracket (6) uprights from frame
bosses and remove throttle cables from recess in
right wire harness caddy.

See

. Slide rubber boot off each cable adjuster

(4).

See

Figure 2-176

. Loosen jamnut (5) on each adjuster

(6). Turn adjusters in direction which will shorten cable
housings to minimum length.

See

ASSEMBLY, XL Models except XL 1200V

. Remove two screws (7) and separate

upper housing (9) from lower housing (11).

Unhook ferrules (1) and cables (2, 3) from throttle control
grip (12) and lower housing (11).

10.

XR 1200X:

See

Figure 2-178

. Disengage cables from

retainer (2) on lower fork bracket. Disengage cables from
loop retainer (3) located under fuel tank.

11. Remove air cleaner assembly. See

4.3 AIR CLEANER

CLEANER ASSEMBLY, XL 1200V

4.3 AIR CLEANER

ASSEMBLY, XR 1200X

12. Disconnect cables from induction module.

13. See

. Remove friction spring (8), throttle fric-

tion screw (13) and spring (5) from lower housing.

sm01214

1. Right wire harness caddy
2. Left wire harness caddy
3. Screw
4. Throttle cables
5. Cable straps
6. Ignition coil bracket

Figure 2-174. Wire Harness Caddy Assembly: XL Models

2013 Sportster Service: Chassis 2-125

sm01826

1. Ferrule (2)
2. Throttle control cable assembly
3. Idle control cable assembly
4. Cable adjuster (2)
5. Spring
6. Retaining ring
7. Screw (2)
8. Friction spring
9. Upper housing
10. Handlebar
11. Lower housing
12. Throttle control grip
13. Throttle friction screw
14. Throttle cable clip
15. Throttle retaining ring
16. Idle retaining ring

Figure 2-175. Throttle Control, Right Handlebar

sm01216

1. Throttle control grip
2. Throttle friction screw
3. Idle control (pull-close) cable
4. Throttle control (pull-open) cable
5. Jamnut (2)
6. Cable adjuster (2)
7. Throttle cam
8. Cam stop
9. Idle control cable guide (on throttle body)
10. Throttle control cable guide (on throttle body)

Figure 2-176. Throttle/Idle Control Cable (typical)

CLEANING AND INSPECTION

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)

2-126 2013 Sportster Service: Chassis

Clean all parts in a non-flammable cleaning solvent. Blow dry
with low pressure compressed air. Replace cables if necessary.

ASSEMBLY AND INSTALLATION

TORQUE VALUE

FASTENER

4.0-5.1 Nm

35-45

in-lbs

Switch housing screw

See

. Apply a light coating of graphite to the

handlebar (10) and the inside surface of the upper and
lower housings (9, 11).

Install spring (5), throttle friction screw (13) and friction
spring (8) in lower housing (11).

Attach cable assemblies (2, 3) to lower housing. See

Figure 2-176

. Throttle control cable (4) has a 5/16 in (7.9

mm) fitting end and is positioned to front of lower housing.
Idle control cable (3) has a 1/4 in (6.3 mm) fitting end and
is positioned to rear of lower housing.

See

. Connect cables:

Install throttle control grip (12) over end of right
handlebar (10).

Position lower housing (11) onto right handlebar,
engaging lower housing with throttle control grip.

Position ferrules (1) over cable ball ends.

Seat ferrules (with cables attached) in their respective
notches of the throttle control grip.

Install upper housing (9) over handlebar. Install the lower
housing using screws (7). Tighten to 35-45

in-lbs

(4.0-5.1

Nm).

XL Models:

See

Figure 2-177

. Route the cables:

Point the cables forward from the throttle control grip
and the front fork upper bracket.

Turn the cables downward between right slider tube
and headlamp.

Route the cables rearward along right side of frame
steering head and frame backbone.

Turn the cables over the ignition switch housing.

Pass the cables between the coil bracket and frame.

Route the cables downward to the induction module.

XR 1200X:

See

Figure 2-178

. Route the cables:

Route the cables forward between right fork and brake
hose (1).

Turn the cables back between the forks above the
lower fork bracket.

Pass the cables through the wire retainer (2) on the
lower fork.

Route the cables above the front cylinder toward the
induction module.

See

Figure 2-176

. Install idle control cable (3) housing

into inboard (idle) cable guide (9) on induction module.

Install throttle control cable (4) housing and spring into
outboard cable guide (10) on induction module.

NOTE

The forward cable strap secures the instrument connector [20].
The rear cable strap secures wiring harnesses on other side
of caddy wall.

10.

XL Models:

See

Figure 2-174

. Place throttle cables (4)

into channel in right wire harness caddy (1). Secure with
two cable straps (5).

Be sure that steering is smooth and free without interfer-
ence. Interference with steering could result in loss of
vehicle control and death or serious injury. (00371a)

11.

XL Models:

See

Figure 2-174

. Mount left wire harness

caddy (2) to right wire harness caddy (1). Secure with
screw (3) and tighten.

Do not pinch the cables between the frame and/or
forks.

Verify that the cables do not pull tight when the
handlebar is turned full lock left and right.

12. Adjust control cables. See

1.13 THROTTLE CONTROL,

Cable Adjustment

13. Install air cleaner assembly.

14. Install fuel tank and connect fuel hose. See

4.4 FUEL

TANK: XL MODELS

4.5 FUEL TANK: XR 1200X

15.

XR 1200X:

See

Figure 2-178

. Secure cables in loop

retainer (3). Attach retainer to the bottom of the fuel tank.

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)

16. Install seat.

17. Install main fuse.

sm01215

Figure 2-177. Throttle Control Cable Routing: XL Models

2013 Sportster Service: Chassis 2-127

sm05332

1. Brake hose
2. Wire retainer
3. Loop retainer

Figure 2-178. Throttle Control Cable Routing: XR 1200X

CONTROLS: XL MID-MOUNT CONTROLS

2-128 2013 Sportster Service: Chassis

2.29

CLUTCH CONTROL

REMOVAL AND DISASSEMBLY

Clutch Cable: Lower

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

Mid-mount Controls:

Remove left side rider footrest and

mounting bracket assembly. See

2.40 RIDER FOOT

2.42 RIDER

FOOT CONTROLS: XR 1200X

See

Figure 2-179

. Slide rubber boot (1) on clutch cable

adjuster (2) upward to expose adjuster mechanism.
Loosen jamnut (3) from adjuster. Turn adjuster to shorten
cable housing until there is a large amount of free play at
clutch hand lever. See

1.11 CLUTCH

See

Figure 2-180

. Remove six screws (1) and clutch

inspection cover (2). Exercise caution to avoid damaging
or dislodging quad ring (7) from groove in primary cover
(9).

Slide hex lockplate with attached spring (3) from flats of
adjusting screw assembly (8).

Turn adjusting screw assembly clockwise to release ramp
assembly (5) and coupling (6). As the adjusting screw is

turned, ramp assembly moves forward. Remove nut (4)
from end of adjusting screw.

Remove hook of ramp from cable coupling. Remove clutch
cable end (11) from slot in coupling. Remove coupling and
ramp assembly.

Remove cable end fitting (12) and clutch cable (13) lower
section from primary cover. Remove O-ring (10) from cable
end fitting. Discard O-ring.

Clean all metal parts in a non-volatile cleaning solution or
solvent.

sm01829

1. Rubber boot
2. Cable adjuster
3. Jamnut
4. Cable end

Figure 2-179. Clutch Cable Adjuster Mechanism

2013 Sportster Service: Chassis 2-129

sm01830

13.

Clutch cable

Quad ring

Screw (6)

14.

Clutch inspection cover

Outer ramp

Clutch adjusting screw
assembly

15.

Hex lockplate and spring

Ball (3)

16.

Primary cover

Inner ramp

Nut

17.

10.

Ramp assembly (see items 14-
17)

Retaining ring

O-ring

11. Clutch cable end

12.

Coupling

Cable end fitting

Figure 2-180. Clutch Release Mechanism

Clutch Lever and Cable: Upper

See

Figure 2-181

. Remove retaining ring (8) and pivot pin

(7). Discard retaining ring.

Remove clutch lever (2) from clutch lever bracket.

Remove clutch cable pin (5). Disconnect clutch cable (6)
upper section from lever.

NOTE

Remove the bushing from the top of the lever.

Remove bushing (1) from clutch lever.

Remove screw (4) and anti-rattle spring (3).

6.18 FRONT TURN SIGNALS, All Except

2-130 2013 Sportster Service: Chassis

sm06833

1. Bushing
2. Lever
3. Anti-rattle spring
4. Screw
5. Clutch cable pin
6. Clutch cable
7. Pivot pin
8. Retaining ring

Figure 2-181. Clutch Lever and Cable

Clutch Hand Control

NOTE

XL 1200X: Leave the turn signals and brackets installed.

All Models except XL 1200X:

Loosen the set screw.

Remove the turn signal assembly from the clutch lever
bracket. See

XL 1200X

See

Figure 2-182

. Loosen and remove the locknut (1),

lockwasher (2) and mirror (3).

NOTE

Loosen the two screws of the left handlebar switch housing to
remove clutch control clamp and clutch lever bracket.

See

Figure 2-182

. Loosen the two screws (4) and washers

(5) with nylon retainers (6) to remove the clutch control
clamp (7).

Remove the clutch lever bracket (8).

sm06834a

1. Locknut
2. Washer
3. Mirror
4. Fastener
5. Washer
6. Nylon retainer
7. Clamp
8. Bracket

Figure 2-182. Clutch Hand Control Clamp and Bracket

(typical)

2013 Sportster Service: Chassis 2-131

ASSEMBLY AND INSTALLATION

TORQUE VALUE

FASTENER

12.2-14.9 Nm

108-132

in-lbs

Handlebar control lever clamp
screw

10.9-16.3 Nm

96-144

in-lbs

Mirror stem locknut

10.9-13.6 Nm

96-120

in-lbs

Turn signal clamp, front, screw

4.0-5.1 Nm

35-45

in-lbs

Switch housing screw

0.9-1.5 Nm

8-13

in-lbs

Clutch lever anti-rattle spring
screw

4.1-12.2 Nm

36-108

in-lbs

Clutch cable fitting

10.2-13.6 Nm

90-120

in-lbs

Clutch inspection cover
screws

61-68 Nm

45-50 ft-lbs

Footrest mount fastener

Clutch Hand Control

Position clutch control clamp and clutch lever bracket onto
left handlebar. Hold clamp and bracket assembly firmly
against left handlebar switch housing.

Secure components to left handlebar using two screws
and washers and retainers. Tighten to 108-132

in-lbs

(12.2-14.9 Nm).

NOTES

•

Adjust the mirrors for rider vision.

•

Adjust the mirrors to not strike the fuel tank on lock to lock
handlebar turns.

XL 1200X: See

Figure 2-183

Install mirror with locknut and lockwasher. Tighten locknut
to 96-144

in-lbs

(10.9-16.3 Nm).

All Models except XL 1200X:

Install turn signal and

secure with set screw. See

6.18 FRONT TURN SIGNALS,

All Except XL 1200X

Position so turn signal lens faces directly forward. Verify
turn signal does not strike fuel tank when the handlebar
is turned full left. Tighten set screw to 96-120

in-lbs

(10.9-

13.6 Nm).

NOTE

If two screws of left handlebar switch housing were loosened
during clutch hand control removal, tighten to 35-45 in-lbs
(4.0-5.1 Nm).

sm06849

1. Locknut
2. Lockwasher
3. Mirror
4. Fastener
5. Washer
6. Nylon retainer
7. Clamp
8. Bracket

Figure 2-183. Clutch Hand Control Bracket: XL 1200X

Clutch Lever and Clutch Cable: Upper

Install anti-rattle spring and screw onto clutch lever.
Tighten screw to 8-13

in-lbs

(0.9-1.5 Nm).

Install bushing in clutch lever. Bushing has a collar on one
end and must be installed from top of lever.

Connect end of clutch cable upper section to clutch lever
using clutch cable pin.

Position lever within clutch lever bracket, install pivot pin
and secure with

new

retaining ring.

Clutch Cable: Lower

XL Models:

See

Figure 2-184

. Route the clutch cable (3):

Forward from clutch lever (1).

Downward to left front fork slider tube. Refer to

Table 2-26

Through two clips (6) on left front frame downtube.

Rearward to the primary cover (4).

2.40 RIDER FOOT CONTROLS: XL MID-MOUNT CON-
TROLS

2-132 2013 Sportster Service: Chassis

XR 1200X:

See

Figure 2-185

. Route the clutch cable:

Down between the fork tubes and clamps.

Downward to inboard side of the left front fork slider
tube.

Through the two clips in the oil cooler mounting
bracket.

NOTE

Check that cable is not pinched between the lower steering
head bracket and frame and the left and right fork stops.

Table 2-26. Clutch Cable Lower Routing Around Left Fork

Slider

NOTES

ROUTE

MODEL

Outboard

XL 883L

Outboard

XL 883N

Outboard

XL 883R

Through the clutch
cable guide

Inboard

XL 1200C/C ANV
XL 1200CP/CA/CB

Inboard

XL 1200X

Inboard

XL 1200V

See

Figure 2-180

. Install

new

O-ring (10) over cable end

fitting (12) of clutch cable (13) lower section. Screw fitting
into primary cover (9). Tighten to 36-108

in-lbs

(4.1-12.2

Nm).

Install coupling (6) over cable end (11) with the rounded
side inboard and the ramp connector button outboard.
With retaining ring side of ramp assembly (5) facing
inward, place hook of ramp around coupling button. Rotate
assembly counterclockwise until tang on inner ramp (16)
fits in slot of primary cover.

Thread nut (4) on adjusting screw assembly (8) until slot
of screw is accessible with a screwdriver. Fit nut hex into
recess of outer ramp (14). Turn adjusting screw counter-
clockwise until resistance is felt. Then back off adjusting
screw 1/4 turn.

Install hex lockplate with spring (3) onto flats of adjusting
screw assembly (8). If necessary, turn adjusting screw
clockwise slightly so that lockplate slides onto flats while
also fitting within recess of outer ramp.

Verify that quad ring (7) is fully seated in groove of primary
cover (9). Install clutch inspection cover (2) and secure
with six screws (1). Tighten screws in a cross pattern to
90-120

in-lbs

(10.2-13.6 Nm).

Models with Mid-mount Controls:

Install left side rider

footrest and mounting bracket assembly. Tighten footrest
bracket mounting screws to 45-50 ft-lbs (61-68 Nm). See

2.42 RIDER FOOT CONTROLS: XR 1200X

Install main fuse.

sm06760

1. Clutch lever
2. Cable adjuster boot
3. Clutch cable
4. Primary cover
5. Cable end fitting
6. Clip (2)

Figure 2-184. Clutch Cable Routing: XL Models

sm06740

Figure 2-185. Clutch Cable Clips: XR 1200X

2.8 FRONT BRAKE MASTER CYLINDER

2013 Sportster Service: Chassis 2-133

2.30

HANDLEBAR

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

All Models

Remove main fuse.

Remove two screws securing clutch control assembly to
left side of handlebar. See

2.29 CLUTCH CONTROL

Remove two screws securing left handlebar switch
assembly to handlebar. See

6.35 LEFT HANDLEBAR

SWITCHES

. Let wires carefully support the switch

assembly.

Remove left handlebar grip. See

2.30 HANDLEBAR, Left

Hand Grip

Remove front brake master cylinder assembly from right
handlebar. See

XL 1200C/C ANV

See

Figure 2-186

. Cut and remove four wiring harness

retainers (1). Discard retainers.

Loosen, but do not remove, two control housings screws.

Remove two screws (2) and riser cover (3).

Remove

four

screws

(6)

and

upper

handlebar

clamp/speedometer housing (7). Detach handlebar from
riser.

Slide right hand control and throttle assembly off the
detached handlebar.

If removing riser (8), remove bolts (4), washers (5) and
riser from upper fork bracket.

XL 1200CP/CA/CB

Pull Back:

See

Figure 2-186

. See

Removal, XL 1200C/C

ANV

Drag Bar:

See

Figure 2-187

. See

Removal, XL 1200C/C ANV

Mini-Ape:

See

Figure 2-187

. See

Removal, All XL Models

except XL 1200C/C ANV

sm07130

1. Wire harness retainer (4)
2. Screw (2)
3. Riser cover
4. Bolt (2)
5. Washer (2)
6. Screw (4)
7. Upper handlebar clamp/speedometer housing
8. Handlebar riser

Figure 2-186. Handlebar: XL 1200C/C ANV/CP Pull Back

sm07103

1. Mini-ape: XL 1200CP/CB
2. Pull back: XL 1200CP
3. Drag: XL 1200CP/CA

Figure 2-187. Handlebars: XL 1200CP/CA/CB

2-134 2013 Sportster Service: Chassis

All XL Models except XL 1200C/C ANV

See

Figure 2-188

. Cut and remove four wiring harness

retainers (1). Be careful not to cut into wiring harnesses.
Discard retainers.

Loosen two control housing screws. Do not remove.

If removing lower handlebar clamps, loosen, but do not
remove, two bolts (2) securing lower handlebar clamps
(6) to upper fork bracket.

Remove screws (4) and the instrument bracket (5).

Detach handlebar from lower handlebar clamps.

Slide right hand control housing and throttle assembly off
detached handlebar.

If removing lower handlebar clamps, remove two bolts,
washers (3) and lower handlebar clamps from upper fork
bracket.

sm05353b

1. Wire harness retainer (4)
2. Bolt (2)
3. Washer (2)
4. Screw (4)
5. Bolt-on instrument bracket/clamp
6. Lower handlebar clamp

Figure 2-188. Handlebar: XL 883L/N/R

XR 1200X

See

Figure 2-189

. Cut and remove four wiring harness

retainers (1). Be careful not to cut into wiring harnesses.
Discard retainers.

Loosen, but do not remove, two right hand control housing
screws.

Remove two front screws (2) and washers (3). Remove
instrument bracket (4).

Remove two rear screws (2) and upper clamp (5).

Detach handlebar from upper fork bracket.

Slide right hand control housing and throttle assembly off
detached handlebar.

sm05354a

1. Wire harness retainer (4)
2. Screw (4)
3. Washer (2)
4. Instrument bracket
5. Upper handlebar clamp

Figure 2-189. Handlebar: XR 1200X

INSTALLATION

TORQUE VALUE

FASTENER

40.7-54.3 Nm

30-40 ft-lbs

Handlebar riser bolt, lower

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp screw

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp screw

0.9-1.4 Nm

8-12

in-lbs

Handlebar riser cover screw

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp screw

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp screw

40.7-54.3 Nm

30-40 ft-lbs

Handlebar riser bolt, lower

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp screw

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp screw

12.2-14.9 Nm

108-132

in-lbs

Handlebar control lever clamp
screw

4.0-5.1 Nm

35-45

in-lbs

Switch housing screw

4.0-5.1 Nm

35-45

in-lbs

Switch housing screw

XL 1200C/C ANV/CP with One-Piece Riser

If the riser was removed, secure the riser to the upper fork
bracket with two bolts and washers. Route the handlebar
wiring inside the riser. Tighten to 30-40 ft-lbs (40.7-54.3
Nm).

Side the right side handlebar control housing and throttle
assembly onto the right end of the handlebar.