Harley Davidson 2013 Sportster Models. Service Manual — page 4

1.5

MAINTENANCE SCHEDULE

GENERAL

TORQUE VALUE

FASTENER

4.5-6.8 Nm

40-60

in-lbs

Air filter screw

4.1-6.8 Nm

36-60

in-lbs

Air cleaner cover screw

6.8-7.9 Nm

60-70

in-lbs

Battery negative terminal
screw

1.0-2.0 Nm

9-17

in-lbs

Brake master cylinder, front,
reservoir cover screws

10.3-13.6 Nm

90-120

in-lbs

Clutch inspection cover
screws

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp screw

4.0-5.1 Nm

35-45

in-lbs

Switch housing screw

4.5-5.1 Nm

40-45

in-lbs

Fuel pump module mounting
screw

27.1-33.9 Nm

20-25 ft-lbs

Chain tensioner nut

10.2-13.6 Nm

90-120

in-lbs

Primary chain inspection cover

19.0-40.7 Nm

14-30 ft-lbs

Primary chaincase drain plug

16.3-24.4 Nm

12-18 ft-lbs

Spark plug

16.3-24.4 Nm

12-18 ft-lbs

Spark plug

6.2 Nm

55

in-lbs

Spoke nipple

At each regular service interval, perform the required mainten-
ance. Refer to

Table 1-4

.

Use the quick reference maintenance chart for torque values,
lubricants or cross references to maintenance procedures.
Refer to

Table 1-5

.

Use the lubricants, greases and sealants table to identify
maintenance supplies. Refer to

Table 1-6

.

Table 1-4. Regular Service Intervals: 2013 Sportster Models

NOTES

50000

MI

80000

KM

45000

MI

72000

KM

40000

MI

64000

KM

35000

MI

56000

KM

30000

MI

48000

KM

25000

MI

40000

KM

20000

MI

32000

KM

15000

MI

24000

KM

10000

MI

16000

KM

5000 MI

8000 KM

1000 MI

1600 KM

PROCEDURE

ITEM SERVICED

3, 7

X

X

X

X

X

X

X

X

X

X

X

Replace

Engine oil and filter

1, 3

X

X

X

X

X

X

X

X

X

X

X

Inspect for leaks,
contact or abrasion

Oil lines and brake
system

7

X

X

X

X

X

X

X

X

X

X

Inspect, service as
required

Air cleaner

3

X

X

X

X

X

X

X

X

X

X

X

Check pressure,
inspect tread

Tires

1, 5, 7

X

X

X

X

X

Check tightness

Wheel spokes
(if equipped)

X

X

X

X

X

X

X

X

X

X

X

Check adjustment

Primary chain

7

X

X

X

X

X

X

Replace

Transmission lub-
ricant

1, 7

X

X

X

X

X

X

X

X

X

X

X

Check adjustment

Clutch

1

X

X

X

X

X

X

X

X

X

X

X

Inspect, adjust belt

Drive belt and
sprockets

1

X

X

X

X

X

X

X

X

X

X

X

Check, adjust and
lubricate

Throttle, brake and
clutch controls

1

X

X

X

X

X

X

X

X

X

X

X

Inspect and lub-
ricate

Jiffy stand

1, 3

X

X

X

X

X

X

X

X

X

X

X

Inspect for leaks,
contact or abrasion

Fuel lines and fit-
tings

1

Replace every 100,000 mi (160,000 km).

Replace

Fuel filter element

4

X

X

X

X

X

X

X

X

X

X

X

Inspect sight glass

Brake fluid

X

X

X

X

X

X

X

X

X

X

X

Inspect for wear

Brake pads and
discs

HOME

1-10 2013 Sportster Service: Maintenance

Table 1-4. Regular Service Intervals: 2013 Sportster Models

NOTES

50000

MI

80000

KM

45000

MI

72000

KM

40000

MI

64000

KM

35000

MI

56000

KM

30000

MI

48000

KM

25000

MI

40000

KM

20000

MI

32000

KM

15000

MI

24000

KM

10000

MI

16000

KM

5000 MI

8000 KM

1000 MI

1600 KM

PROCEDURE

ITEM SERVICED

1, 6

X

X

X

X

X

X

X

X

Inspect

Front brake lever
pin

1, 6

X

X

Lubricate

Front brake lever
pin

1, 6

X

X

X

X

X

X

X

X

Inspect

Brake caliper pins

1, 6

X

X

Lubricate

Brake caliper pins

1, 6

X

X

X

X

X

X

X

X

Inspect

Brake caliper boots
and bushings

1, 6

X

X

Replace

Brake caliper boots
and bushings

1, 6

X

X

X

X

X

X

X

X

X

X

Inspect

Rear master cyl-
inder outer boot

1, 6

X

X

Replace brake
rubber components
in master cylinders
and calipers

Brake components

1, 6

X

X

Lubricate master
cylinder pistons

Brake components

8

X

Replace

Spark plugs

X

X

X

X

X

X

X

X

X

X

X

Check operation

Electrical equip-
ment and switches

1, 9

X

Rebuild

Front forks

1, 2

X

X

X

Adjust

Steering head
bearings

1

Inspect every 30,000 mi (48,000 km)

Rear fork bearings

1

X

X

X

X

X

X

Check tightness

Critical fasteners

1

X

X

X

X

X

Inspect

Engine mounts and
stabilizer links

Check battery and clean connections annually.

Battery

3, 7

X

X

X

X

X

X

X

X

X

X

X

Inspect for leaks,
cracks, and loose
or missing
fasteners or heat
shields

Exhaust system

X

X

X

X

X

X

X

X

X

X

X

Verify component
and system func-
tions

Road test

1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified.

NOTES:

2. Disassemble, lubricate and inspect every 30,000 mi (48,000 km).
3. Perform annually or at specified intervals, whichever comes first.
4. Replace DOT 4 hydraulic brake fluid and flush system every two (2) years.
5. Perform spoke tension check at 1000 mi (1600 km), 5000 mi (8000 km), 20,000 mi (32,000 km) services and every 15,000 mi (24,000 km)
interval thereafter. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.
6. Replace every four (4) years or at specified intervals, whichever comes first.
7. Perform maintenance more frequently in severe riding conditions (such as extreme temperatures, dusty environments, mountainous or rough
roads, long storage conditions, short runs, heavy stop/go traffic or poor fuel quality).
8. Replace every two (2) years or at specified intervals, whichever comes first.
9. Disassemble, inspect, rebuild forks and replace fork oil every 50,000 mi (80,000 km).

Table 1-5. Quick Reference Maintenance Chart

DATA

SPECIFICATION

ITEM SERVICED

See

1.7 AIR FILTER

Air cleaner

40-60

in-lbs

(4.5-6.8 Nm)

Air filter screw torque: XL Models

36-60

in-lbs

(4.1-6.8 Nm)

Air cleaner cover screw torque: XL Models

Electrical Contact Lubricant

Lubricant

Battery

60-70

in-lbs

(6.8-7.9 Nm)

Terminal screw torque

HOME

2013 Sportster Service: Maintenance 1-11

Table 1-5. Quick Reference Maintenance Chart

DATA

SPECIFICATION

ITEM SERVICED

DOT 4 Brake Fluid

Brake fluid type

Brake fluid reservoir level
(Check sight glass. If fluid
is low, remove reservoir
cover and re-check.)

1/4 in (6.35 mm) from the top of the reservoir

Proper fluid level (front brake)

Upper fluid level in reservoir

Proper fluid level (rear brake)

9-17

in-lbs

(1.0-2.0 Nm)

Front master cylinder reservoir cover screw torque

0.04 in (1.02 mm)

Minimum brake pad thickness

Brake pad linings and discs

See stamp on side of disc.

Minimum brake disc thickness

1/4 turn

Free play at adjuster screw

Clutch adjustment

1/16-1/8 in (1.6-3.2 mm)

Free play at hand lever

90-120

in-lbs

(10.3-13.6 Nm)

Clutch inspection cover screw torque

Harley Lube

Lubricant

Clutch and throttle cables

12-18 ft-lbs (16.3-24.4 Nm)

Handlebar clamp screw torque

35-45

in-lbs

(4.0-5.1 Nm)

Switch housing screw torque

See

1.20 CRITICAL FASTENERS

.

Critical fasteners

10 lb (4.5 kg)

Apply upward measurement force at midpoint of
bottom belt strand.

Drive belt

XL 883L/XL 883N/XL 1200X/XL 1200V/XL
1200C/C ANV/XL 1200CP/XL 1200CA/XL
1200CB:

Belt deflection with motorcycle on jiffy stand, belt
and sprockets at ambient temperature (cold engine),
without rider or luggage

1/4-5/16 in (6.35-7.94 mm)

XL 883R: 9/16-5/8 in (14.3-15.9 mm)

XR 1200X: 1/4-3/8 in (6.4-9.5 mm)

Belt deflection measurement taken midway between
rear sprocket and idler

950-1050 rpm

Idle speed

Engine idle speed

See

2.26 FRONT ENGINE MOUNT/ISOLATOR

,

2.27 REAR ENGINE MOUNT/ISOLATOR

, and

2.25 STABILIZER LINKS

.

Engine mounts/isolators
and stabilizers

2.8 qt (2.65 L)

Oil capacity

Engine oil and filter

Hand tighten 1/2-3/4 turn after gasket contact.

Filter

Type "E" Hydraulic Fork Oil

Type

Front fork oil: XL Models

See

2.19 FRONT FORK: XL MODELS,

Assembly

.

Amount

Big Piston Fork Oil

Type

Front fork oil: XR 1200X

See

2.20 FRONT FORK: XR 1200X, Assembly

.

Amount

40-45

in-lbs

(4.5-5.1 Nm)

Fuel pump module mounting screw torque

Fuel filter

1/4-3/8 in (6.3-9.5 mm)

Deflection with hot engine

Primary chain tension

3/8-1/2 in (9.5-12.7 mm)

Deflection with cold engine

20-25 ft-lbs (27.1-33.9 Nm)

Chain tensioner nut torque

90-120

in-lbs

(10.2-13.6 Nm)

Primary chain inspection cover screw torque

32 oz (946 mL)

Lubricant capacity

Primary chain/transmission
lubricant

14-30 ft-lbs (19.0-40.7 Nm)

Primary chaincase drain plug torque

Genuine Harley-Davidson Formula+ Transmis-
sion and Primary Chaincase Lubricant

Lubricant

6R12

Type

Spark plugs: XL Models

0.038-0.043 in (0.96-1.09 mm)

Gap

12-18 ft-lbs (16.3-24.4 Nm)

Torque

HOME

1-12 2013 Sportster Service: Maintenance

Table 1-5. Quick Reference Maintenance Chart

DATA

SPECIFICATION

ITEM SERVICED

10R12X

Type

Spark plugs: XR 1200X

0.032-0.038 in (0.81-0.97 mm)

Gap

12-18 ft-lbs (16.3-24.4 Nm)

Torque

Special Purpose Grease

Lubricant

Steering head bearings

Front: 36 psi (248 kPa)

XL 883L

Tire condition and pressure

Rear: 42 psi (290 kPa)

Front: 30 psi (207 kPa)

XL Models (except XL 1200X/C/C ANV/CP/CA/CB)

Rear: 40 psi (276 kPa)

Front: 36 psi (248 kPa)

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

Rear: 40 psi (275 kPa)

Front: 36 psi (248 kPa)

XR 1200X

Rear: 42 psi (290 kPa)

Replace tire if 1/32 in (0.8 mm) or less of tread
pattern remains.

Wear

55

in-lbs

(6.2 Nm)

Spoke nipple torque

Wheel spokes

HOME

2013 Sportster Service: Maintenance 1-13

Table 1-6. Lubricants, Greases, Sealants

PACKAGE

PART NUMBER

ITEM

5 oz tube

021200-19718 *

3M 847 Adhesive

15 oz. aerosol

3M General Purpose Adhesive Remover

1 oz squeeze tube

98960-97

Anti-Seize Lubricant

16 oz bottle

62600029

Big Piston Fork Oil (Sportster XR only)

squeeze packet (included in master cylinder
rebuild kit)

42830-05

CCI #20 Brake Grease

12 oz bottle

99953-99A

DOT 4 Brake Fluid

2 cc packet

94674-99

Dow Corning Moly 44 Grease

1 oz squeeze tube

99861-02

Electrical Contact Lubricant

1 qt bottle

99851-05

Formula+ Transmission and Primary Chaincase
Lubricant

squeeze packet

42820-04

G40M Brake Grease

1 gal container

99822-02

Genuine Harley-Davidson Extended Life Antifreeze
and Coolant (V-Rod only)

1 qt bottle

99816-2050/00QT

Genuine Harley-Davidson H-D 360 20W50
Motorcycle Oil

10 g tube

99839-95

Harley-Davidson Adhesive (Griplock)

1.9 oz squeeze tube

99650-02

Harley-Davidson High Performance Sealant - Gray

6 oz can

98261-91V

Harley-Davidson Leather Dressing

1 oz tube

11300005

Harley-Davidson Seal Grease

1/4 oz needle dispenser

94968-09

Harley® Lube

3.5 oz tube

99653-85

Hylomar Gasket and Thread Sealant

6 mL tube

99811-97

Loctite 222 Low Strength Threadlocker and Sealant (purple)

6 mL tube

99642-97

Loctite 243 Medium Strength Threadlocker and Sealant (blue)

50 mL bottle

11100005

Loctite 246 Medium Strength/High Temperature Threadlocker
(blue)

6 mL tube

94759-99

Loctite 262 High Strength Threadlocker and Sealant (red)

50 mL bottle

11100006

Loctite 411 Prism Instant Adhesive

Loctite 420 Super Bonder Adhesive

6 mL tube

99818-97

Loctite 565 Thread Sealant

Loctite 770 Prism Primer

1.75 oz bottle

98968-99

Loctite 7649 Cleaner/Primer

1.9 oz tube

99650-02

RTV Silicone Sealer

4 oz bottle

94971-09

Screamin' Eagle Assembly Lube

1 qt bottle

99824-03/00QT

Screamin' Eagle SYN3 Full Synthetic Motorcycle
Lubricant 20W50

14 oz cartridge

99857-97A

Special Purpose Grease

16 oz bottle

62600026

Type "E" Hydraulic Fork Oil

1 lb can

99855-89

Wheel Bearing Grease

14 oz cartridge

99856-92

* Not a Harley-Davidson part number

HOME

1-14 2013 Sportster Service: Maintenance

1.6

ENGINE OIL AND FILTER

CHECKING AND ADDING OIL

Removing and Replacing Oil Filler Cap

1.

Park the motorcycle on level ground on the jiffy stand.

2.

See

Figure 1-1

. Remove the filler cap from the oil tank.

a.

Press straight down on the filler cap and release. The
cap will pop up.

b.

Pull up on the filler cap while turning counterclockwise
one-quarter turn as if removing the filler cap.

3.

Wipe the dipstick clean.

NOTE

See

Figure 1-2

. Align tabs on oil tank filler neck to slots (1, 2)

on dipstick.

4.

Insert the dipstick into the tank.

a.

Turn the filler cap clockwise one-quarter turn as if
screwing the filler cap into tank. When the filler cap
stops turning, it is seated.

b.

Press down on the filler cap until it snaps in place,
flush with the top of the oil tank cover.

om00907

Figure 1-1. Filler Cap Location

2

1

om00200

1. Wide slot
2. Narrow slot

Figure 1-2. Filler Cap Slots

Oil Level Cold Check

NOTES

Check engine oil level at each complete fuel refill.

An accurate engine oil check can only be made with the
engine at operating temperature (Hot Check).

1.

Park the motorcycle on level ground on the jiffy stand.

2.

Remove the filler cap and wipe the dipstick clean. Install
the oil filler cap in tank.

3.

Remove oil filler cap again and visually check for oil in the
tank.

4.

If oil is not visible in the tank, install the filler cap.

NOTE

If the oil pressure lamp stays lit after starting engine, immedi-
ately shut the engine off.

5.

Start and idle the engine for 30 seconds. Stop the engine.

6.

Remove oil filler cap and visually check for oil in the tank.

Do not overfill oil. Doing so can result in oil carryover to
the air cleaner leading to equipment damage and/or
equipment malfunction. (00190b)

NOTE

Use only recommended oil. Recommended viscosity depends
upon ambient temperature. Refer to

Table 1-2

.

7.

If there is no oil visible in the tank, add oil until it is present
on the bottom of the dipstick.

HOME

2013 Sportster Service: Maintenance 1-15

8.

When oil is present on the bottom of the dipstick, perform
a hot check.

Oil Level Hot Check

1.

Run the engine until the engine oil is at operating temper-
ature.

2.

Idle the motorcycle on the jiffy stand for one to two
minutes. Turn the engine off.

3.

Park the motorcycle on level ground on the jiffy stand.

4.

Remove the filler cap. Wipe the dipstick clean and install
the filler cap in the tank.

Do not allow hot oil level to fall below Add/Fill mark on
dipstick. Doing so can result in equipment damage and/or
equipment malfunction. (00189a)

NOTES

Use only recommended oil. Recommended viscosity
depends upon ambient temperature. Refer to

Table 1-2

.

Do not overfill the oil tank. The oil tank has a built-in
pressure relief valve. If the oil tank is overfilled, excessive
pressure is created in the oil tank. The pressure relief valve
will open to relieve the pressure and prevent damage to
the oil tank. Excessive oil due to overfilling will also be
forced out the pressure relief valve when it opens.

Do not overfill oil. Doing so can result in oil carryover to
the air cleaner leading to equipment damage and/or
equipment malfunction. (00190b)

5.

See

Figure 1-3

. Remove the filler cap and check the hot

oil level on the dipstick.

a.

Below the lower mark:

Add only enough oil until the

level reads between the upper and lower marks.

b.

Between the upper and lower marks:

It is safe to

operate the motorcycle.

c.

At (or above) the upper mark:

Drain the oil until the

level reads between the upper and lower marks.

6.

Install the filler cap.

7.

If oil was added, remove the filler cap and verify the engine
oil level in the oil tank. Do not fill oil tank to a level above
upper mark on the dipstick. Install the filler cap.

2

1

om00999a

1. Lower mark (FILL)
2. Upper mark (FULL)

Figure 1-3. Dipstick

CHANGING OIL AND FILTER

TOOL NAME

PART NUMBER

HARLEY-DAVIDSON OIL FILTER
WRENCH

HD-42311

HARLEY-DAVIDSON OIL FILTER
WRENCH

HD-44067-A

TORQUE VALUE

FASTENER

0.7-1.1 Nm

6-10

in-lbs

Oil drain hose worm clamp

Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)

Completely drain oil tank of used oil at scheduled service
intervals. Refill with fresh oil. Refer to

Table 1-4

.

NOTES

Change oil at specified intervals in normal service at warm
or moderate temperatures.

Change engine oil at shorter intervals in cold weather or
in severe operating conditions. See

1.3 FUEL AND OIL,

Winter Lubrication

.

Change engine oil at shorter intervals if ridden extremely
hard, used in competition, or driven on dusty roads.

Always change oil filter when changing engine oil.

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

Draining Oil Tank

1.

Run engine until engine oil has reached normal operating
temperature.

HOME

1-16 2013 Sportster Service: Maintenance

2.

Remove dipstick from oil tank. Oil will drain faster when
the dipstick is removed.

3.

See

Figure 1-4

. Place a suitable container directly under

the drain hose (1) at the bottom rear of the engine crank-
case. The container must be able to hold approximately
3.0 qt (2.8 L).

4.

Loosen worm drive clamp (2). Pull drain plug (3) from end
of drain hose. Completely drain engine oil from oil tank.
Drain engine crankcase only if needed.

5.

Install drain plug into end of drain hose. Tighten worm
drive clamp to 6-10

in-lbs

(0.7-1.1 Nm).

2

3

1

sm01684

1. Oil tank drain hose
2. Worm drive clamp
3. Drain plug

Figure 1-4. Oil Tank Drain Hose

Removing Oil Filter

1.

Place a drain pan beneath front of engine crankcase.

Use Harley-Davidson oil filter wrench for filter removal.
This tool can prevent damage to crankshaft position sensor
and/or sensor cable. (00192b)

2.

See

Figure 1-5

and

Figure 1-6

. Remove oil filter using

HARLEY-DAVIDSON OIL FILTER WRENCH (Part No. HD-
42311) or HARLEY-DAVIDSON OIL FILTER WRENCH
(Part No. HD-44067-A). Turn oil filter counterclockwise to
remove from filter mount.

3.

Drain oil filter into drain pan. Discard oil filter.

4.

Clean any oil spills off crankcase and frame.

NOTE

Dispose of oil and oil filter in accordance with local regulations.

sm01673

Figure 1-5. Oil Filter Wrenches

2

1

sm03917

1. Oil filter mount
2. Oil filter

Figure 1-6. Oil Filter

Installing Oil Filter

NOTE

Minimize the time required for buildup of oil pressure when
engine is first started. Partially fill oil filter before installation.

1.

Pour about 4 fl oz (120 mL) of fresh, clean engine oil into

new

oil filter. Allow time for oil to soak into filter element.

2.

See

Figure 1-7

. Wipe filter gasket contact surface of oil

filter mount with a clean cloth. Surface should be smooth
and free of any debris or old gasket material.

3.

Apply a thin film of oil to gasket contact surface on crank-
case (3) and gasket surface of

new

oil filter.

NOTE

Do not use oil filter wrench to install new oil filter.

4.

Install

new

oil filter. Screw filter clockwise onto adapter

until gasket contacts the filter mount surface. Then hand
tighten an additional 1/2-3/4-turn to secure the oil filter.

HOME

2013 Sportster Service: Maintenance 1-17

10. Verify timing marks. If necessary, remove a cam, rotate it

slightly and replace it. If timing marks are off even one
tooth, engine will not run correctly.

11. Lubricate all cam bores in gearcase cover with engine oil.

12. See

Figure 3-168

. Install gearcase cover with

new

gasket

and secure with three fasteners (6). Tighten fasteners to
90-120

in-lbs

(10.2-13.6 Nm).

13. Install oil pump rotors. Orient the rotors as removed.

14. Install

new

O-rings in oil pump cover and install using six

fasteners (4). Tighten to 90-120

in-lbs

(10.2-13.6 Nm).

15. Install check valve housing using a new base O-ring.

Tighten fasteners (3) to 90-120

in-lbs

(10.3-13.6 Nm).

16. Connect rigid lines (1) and vent hose (2). See

3.12 PRE-

CISION COOLING SYSTEM: XR 1200X, Oil Pump Lines

.

17. See

Figure 3-169

. Install gearcase and oil pump cover.

Secure with 9 socket fasteners. Tighten in the sequence
shown to 90-120

in-lbs

(10.2-13.6 Nm).

18. Gauge cam gear end play. See

3.17 BOTTOM END

OVERHAUL: DISASSEMBLY, Cam Gear End Play

.

sm05013c

Figure 3-167. Cam and Pinion Gear Timing Marks: XR 1200X (V-marks are not used for timing)

1

1

5

4

3

2

6

6

sm05004a

1. Rigid lines
2. Vent hose
3. Check valve screws (2)
4. Oil pump cover screw (6)
5. Oil pump cover
6. Gearcase cover fastener (3)

Figure 3-168. Gearcase Cover and Oil Pump: XR 1200X

7

3

1

5

4

2

6

8

9

sm05017a

Figure 3-169. Oil Pump Cover Torque Sequence: XR 1200X

HOME

2013 Sportster Service: Engine 3-117

TAPPETS

TORQUE VALUE

FASTENER

10.2-13.6 Nm

90-120

in-lbs

Tappet cover, anti-rotation
mounting screw

General

See

Figure 3-170

. The tappet and roller (4), under compression

force from valve spring, follow the surface of the revolving cam.
The up-and-down motion is transmitted to the valve by the
pushrod and rocker arm. The tappet contains a piston (2) and
cylinder. The check valve (3) allows the unit to fill with engine
oil (1) reducing clearance in the valve train. The unit automat-
ically compensates for heat expansion to maintain minimal
clearances between the cam and the pushrod.

It is normal for tappets to click when engine is started after
standing for some time. Tappets have a definite leakdown rate
which permits the oil in the tappets to escape. This allows units
to compensate for various expansion conditions of parts and
still maintain minimal clearances. Tappets are functioning
properly if they become quiet after a few minutes of engine
operation.

1

2

1

3

4

sm01597

1. Oil
2. Piston
3. Check valve
4. Roller

Figure 3-170. Tappet Assembly

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)

1.

Clean all parts, except roller/tappet assembly, in solvent.
Blow dry with compressed air.

2.

Measure valve tappet OD and crankcase bore ID to calcu-
late clearance. If guide clearance exceeds specification,
replace the tappets and/or crankcases. Refer to

Table 3-43

.

3.

Measure tappet roller free play. Recommended service
practice is tappet replacement.

4.

Measure tappet roller end clearance.

5.

Soak tappets in clean engine oil and kept covered until
assembly.

6.

Apply SCREAMIN' EAGLE ASSEMBLY LUBE to rollers
and OD of tappet before installation.

Table 3-43. Valve Tappet Specifications

SERVICE WEAR LIMIT

ITEM

mm

in

0.076

0.0030

Tappet clearance in guide

0.038

0.0015

Tappet roller free play
(clearance on pin)

0.660

0.026

Tappet roller end clearance

Installation

1.

See

Figure 3-171

. Rotate engine so that both tappets (3)

from the cylinder being serviced will be installed on the
base circle (lowest position) of the cam.

2.

Apply a liberal amount of engine oil to tappet assembly
(especially roller needles) for smooth initial operation.

NOTE

Face the flats of the tappets front and rear when installed in
the engine and with the oil feed hole toward the gear cover.

3.

Insert the intake and exhaust tappets into the anti-rotation
blocks (2).

4.

Install anti-rotation blocks with tappets into bore in right
crankcase (4). Secure with screw (1). Tighten to 90-120

in-lbs

(10.2-13.6 Nm).

NOTE

The front tappet cover has a tab on the front or right side. The
rear tappet cover has a tab on the rear or left side.

5.

Install the tappet covers, pushrod covers, and pushrods.
See

3.16 TOP END OVERHAUL: ASSEMBLY, Tappet

Covers, Pushrod Covers and Pushrods

.

HOME

3-118 2013 Sportster Service: Engine

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Политика конфиденциальности