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
.
Use the quick reference maintenance chart for torque values,
lubricants or cross references to maintenance procedures.
Refer to
.
Use the lubricants, greases and sealants table to identify
maintenance supplies. Refer to
.
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
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
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
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
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
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
.
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
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
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
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
. 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
. 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
.
7.
If there is no oil visible in the tank, add oil until it is present
on the bottom of the dipstick.
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
.
•
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
. 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
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
.
•
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.
1-16 2013 Sportster Service: Maintenance
2.
Remove dipstick from oil tank. Oil will drain faster when
the dipstick is removed.
3.
See
. 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
and
. 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
. 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.
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
. 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
CISION COOLING SYSTEM: XR 1200X, Oil Pump Lines
17. See
. 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
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
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
. 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
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
. 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
3-118 2013 Sportster Service: Engine
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