Harley Davidson 2013 Sportster Models. Service Manual — page 23
3.3
OIL PRESSURE
OPERATION
All Models
When an engine is cold, the engine oil is more viscous (thicker).
During start-up, oil pressure will be higher than normal and oil
circulation will be somewhat restricted. As the engine warms
to normal operating temperature, the engine oil warms up and
becomes less viscous. The oil pressure decreases.
•
Increased engine speed results in higher oil pressure. The
faster the oil pump rotors spin, the greater the volume of
circulated oil.
•
Decreased engine speed lowers the volume of oil pumped
and the measured oil pressure.
XL Models
The oil pump is non regulatory and delivers its entire volume
of oil under pressure to the oil filter mount.
XR 1200X
The feed oil pump incorporates a bypass valve that will open
at approximately 50 psi (345 kPa), preventing overpressure in
the oil cooler and related components. The XR 1200X incorpor-
ates a thermostat in the oil cooler return path.
Oil Pressure Indicator Lamp
See
. The oil pressure indicator lamp turns on to
indicate improper circulation of the engine oil.
Refer to
. The oil pressure indicator lamp turns on
when:
•
Ignition switch is turned on prior to starting engine.
•
Oil is not circulating through the running engine.
•
Oil pressure is abnormally low on the running engine.
•
Engine is idling far below 1000 rpm.
The oil pressure indicator lamp turns off when oil is circulating
with adequate pressure through the engine running at 1000
rpm or greater.
sm02321
Figure 3-1. Oil Pressure Indicator Lamp
If the oil pressure indicator lamp remains lit, always check
the oil supply first. If the oil supply is normal and the lamp
is still lit, stop the engine at once and do not ride further
until the trouble is located and the necessary repairs are
made. Failure to do so may result in engine damage.
(00157a)
NOTE
Residual oil pressure in the filter housing will sometimes pre-
vent the lamp from turning on. This may occur when cycling
the ignition key to on after stopping the engine.
Table 3-20. Oil Lamp Troubleshooting
PROBABLE CAUSES
OIL PRESSURE INDICATOR LAMP
Empty oil tank.
Stays on at speeds above idle.
Clogged feed line (ice and sludge, freezing temperatures).
Air-bound oil line.
Grounded oil pressure switch wire.
Malfunctioning oil pressure switch.
Diluted oil.
Malfunctioning check valve. See
and
COOLING SYSTEM: XR 1200X, Cylinder Head Oil Feed Assembly
Malfunctioning or improperly installed pressure relief valve.
Incorrect idle speed. Malfunctioning or improperly installed check valve. See
and
3.12 PRECISION COOLING SYSTEM: XR 1200X, Cylinder
Flickers at idle.
Malfunctioning or improperly installed pressure relief valve.
3-10 2013 Sportster Service: Engine
Table 3-20. Oil Lamp Troubleshooting
PROBABLE CAUSES
OIL PRESSURE INDICATOR LAMP
Malfunctioning signal switch.
Does not glow when ignition is turned on
(prior to operating engine).
Malfunction in wiring.
Burned-out signal bulb.
Dead battery.
See NOTE before this table.
CHECKING OIL PRESSURE
TOOL NAME
PART NUMBER
OIL PRESSURE SENDING UNIT
WRENCH
HD-41675
OIL PRESSURE GAUGE ADAPTER
HD-96921-125
OIL PRESSURE TEST GAUGE KIT
HD-96921-52D
OIL PRESSURE GAUGE ADAPTER
HD-96925-58
1.
Fill oil tank to proper level. See
2.
Slide a catch pan under the motorcycle.
3.
Obtain OIL PRESSURE TEST GAUGE KIT (Part No. HD-
96921-52D).
Connecting Gauge: XL Models
1.
See
. Detach wiring from oil pressure indicator
lamp switch (2).
2.
Using OIL PRESSURE SENDING UNIT WRENCH (Part
No. HD-41675), remove oil pressure switch.
3.
See
. Install OIL PRESSURE GAUGE
ADAPTER (Part No. HD-96925-58) (2) in oil pressure
indicator lamp switch mounting hole. Tighten adapter
snugly. DO NOT OVER-TIGHTEN.
Connecting Gauge: XR 1200X
1.
See
. Disconnect the quick connect fitting from
the inlet side of the oil cooler (4). See
COOLING SYSTEM: XR 1200X, General
.
2.
Connect OIL PRESSURE GAUGE ADAPTER (Part
No. HD-96921-125) (5) to the oil hose (6).
3.
Connect the other end of the adapter to the oil cooler fitting
(4).
Testing Pressure
1.
See
or
. Assemble banjo bolt (2),
washer (3), OIL PRESSURE GAUGE banjo fitting (1) and
second washer onto adapter and tighten snugly.
NOTE
For an accurate reading, engine oil should be at normal oper-
ating temperature: 230 °F (110 °C).
2.
Temporarily secure oil pressure gauge and hose to
motorcycle frame with cable straps. Verify gauge and hose
assembly do not interfere with normal operation. Ride
motorcycle until engine reaches normal operating temper-
ature.
3.
Check and record the pressure readings at normal idle
(approximately 1000 rpm) and again at 2500 rpm. Refer
to
Table 3-21. Oil Pressure: At OperatingTemperature
XR 1200X**
XL MODELS*
rpm
kPa
psi
kPa
psi
110.3-137.9
16-20
43.3-82.7
7-12
1000
275.8-303.4
40-44
68.9-117
10-17
2500
* Pressure reading taken at oil pressure switch fitting.
** Pressure reading taken at oil cooler inlet.
Removing Gauge: XL Models
1.
Stop engine. Remove OIL PRESSURE GAUGE assembly
from oil pressure indicator lamp switch mounting hole in
crankcase. Cut cable straps securing gauge and hose.
Remove banjo bolt, gauge assembly, washers and adapter
from vehicle.
2.
See
. Coat threads of oil pressure switch (2)
with LOCTITE 565 PIPE SEALANT with TEFLON. Replace
the oil pressure switch. Using OIL PRESSURE SENDING
UNIT WRENCH, tighten switch snugly. DO NOT OVER-
TIGHTEN.
3.
Plug in connector [120] (3) by pushing elbow connector
straight up onto stud on oil pressure switch.
Removing Gauge: XR 1200X
1.
Stop engine. Cut cable straps securing gauge and hose.
Remove banjo bolt, gauge assembly, washers and adapter
from vehicle.
2.
Connect oil hose to oil cooler fitting, making sure it is
securely latched.
Finalize Test
NOTE
If an appreciable amount of oil leaked out when oil pressure
switch was removed, replace with fresh oil.
1.
Check oil level in oil tank. See
. Top off oil level if necessary.
2.
Start engine. Test oil pressure switch for proper operation.
Check for oil leaks.
2013 Sportster Service: Engine 3-11
3.4
CRANKCASE BREATHING SYSTEM
XL MODELS
See
. On the piston downstroke, a mixture of crank-
case air and oil mist is vented up the pushrod covers (1)
through a breather valve (2) in each inner rocker box section.
The oil mist separates from the crankcase air, collects and
passes through a small drain hole adjacent to the exhaust valve
in the head where it eventually returns to the crankcase.
The crankcase air is routed through a passage in each cylinder
head. The crankcase air then travels through each air cleaner
backing plate mounting bolt (3) into the filtered side of the air
cleaner.
3
1
2
sm06838
1. Pushrod cover
2. Breather valve
3. Air cleaner backing plate bolt
Figure 3-6. Crankcase Breathing System: XL Models
XR 1200X
See
. During the piston downstroke, internal crank-
case pressure increases. Crankcase air/oil mist (9) is forced
into the area around the rocker arms and valve springs. The
vapor travels through two passages (6) in the inner rocker
cover. Then into a cavity (7) between the cylinder head and
inner rocker cover. The vapor then moves into the filter media
(8) of the breather valve (3).
The oil-laden vapor passes through the filter media (8) of the
breather valve assembly. The oil separates from the crankcase
air and drains back into cavity (7). There it flows toward the
exhaust valve. The oil then passes through a small drain hole
adjacent to the exhaust valve and returns to the crankcase.
Air pressure forces the breather umbrella valve (5) to open.
Air flows through a fitting (4) in the outer rocker cover. The
umbrella valve prevents the air from moving back into the
crankcase during piston upstroke. Air travels through a vapor
hose (2) connected to a hose and tee assembly (10) in the air
box. The air eventually exits into the intake air stream above
the induction module. The air is consumed by the engine.
6
1
10
7
9
2
4
3
9
8
5
sm06839
1. Rocker cover
2. Vapor hose
3. Breather valve assembly
4. Vapor hose fitting
5. Umbrella valve
6. Passage
7. Cavity
8. Filter media
9. Vapor from crankcase
10. Hose and tee
Figure 3-7. Crankcase Breathing System: XR 1200X
2013 Sportster Service: Engine 3-13
3.5
TROUBLESHOOTING
DIAGNOSING VALVE TRAIN NOISE
To diagnose and correct noisy hydraulic lifters and valve train
components, use the following procedures:
1.
With engine and oil at normal operating temperature, check
oil pressure at 2000 rpm. If oil pressure is above 50 psi
(345 kPa) or below 5 psi (34 kPa), inspect oil pump,
crankcase passages and oil hoses. Repair or replace parts
as necessary.
2.
If oil is reaching the hydraulic lifters, remove and inspect.
Clean lifter bore of all foreign material. Replace parts as
necessary. See
.
3.
Examine pushrod, lifter and lifter bore for proper fit and
any signs of unusual wear. Replace parts as necessary.
4.
Visually inspect camshaft lobes for abnormal wear.
5.
Remove camshafts and pinion gear, clean and inspect for
wear and fit. Replace parts as necessary.
6.
Remove cylinder head and rocker box assemblies. Check
rocker arm end play and check for binding. Inspect valve
stems for scuffing and check stem to guide clearance.
Check valve seats for signs of looseness or shifting.
7.
Face valves and valve seats.
COMPRESSION TEST
TOOL NAME
PART NUMBER
CYLINDER COMPRESSION GAUGE
HD-33223-1
Combustion chamber leakage may cause performance issues.
A compression test can help determine the source of cylinder
leakage.
Test engine at normal operating temperature
1.
Disconnect spark plug wires.
2.
Clean around spark plug base. Remove spark plugs.
3.
Connect CYLINDER COMPRESSION GAUGE (Part
No. HD-33223-1) to front cylinder.
4.
Make sure transmission is in neutral. With throttle plate in
wide open position, crank engine continuously through 5-
7 full compression strokes.
5.
Note gauge readings at the end of the first and last com-
pression strokes. Record test results.
6.
Connect the gauge to the rear cylinder and repeat test.
a.
Compression is normal if final readings are within
specification and do not indicate more than a 10 psi
(0.689 bar) variance between cylinders. Refer to
b.
Compression is below specification if the readings
are 100 psi (6.89 bar) for 883 cc engines or 150 psi
(10.3 bar) for 1200 cc engines. Refer to
7.
Inject approximately 1/2 oz (15 mL) SAE 30 engine oil into
each cylinder and repeat the compression tests on both
cylinders. Readings that are considerably higher during
the second test indicate worn piston rings.
NOTE
Verify throttle plate is in the closed position after testing.
Table 3-22. Normal Compression Ranges
COMPRESSION
ENGINE
bar
psi
11.4-12.4
165-180
XL 883
13.8-15.5
200-225
XL 1200
11.7-12.8
170-185
XR 1200X
Table 3-23. Compression Test Results
CAUSE
TEST RESULTS
Ring trouble
Compression low on first stroke, builds
up on the following strokes, but does not
reach normal. Improves when oil is
added to cylinder.
Valve trouble
Compression low on first stroke, does
not build up on following strokes. Does
not improve with the addition of oil.
Head gasket leak
Incorrect pushrod
length
CYLINDER LEAKAGE TEST
TOOL NAME
PART NUMBER
CYLINDER LEAKDOWN TESTER
HD-35667-A
The cylinder leakage test pinpoints engine problems including
leaking valves, worn, damaged or stuck piston rings and blown
head gaskets.
Use CYLINDER LEAKDOWN TESTER (Part No. HD-35667-
A). Follow the specific instructions supplied with the tester.
1.
Run engine until it reaches normal operating temperature.
2.
Clean around spark plug base. Remove spark plugs.
3.
Remove the air cleaner and set the throttle in the wide
open position.
4.
Rotate the piston to TDC of the compression stroke (both
valves closed).
5.
To keep the crankshaft from turning when air pressure is
applied to the cylinder, engage transmission in fifth gear
and lock the rear brake.
NOTE
Before performing the cylinder leakage test, verify that the
tester itself is free from leakage. Apply a soap solution around
the tester fittings. Connect the cylinder leakdown tester to the
compressed air source. Look for any bubbles that would
indicate leakage from the tester.
3-14 2013 Sportster Service: Engine
6.
Following the manufacturer's instructions, perform a cyl-
inder leakage test. Make a note of the percent of leakage.
Leakage greater than 12 percent indicates internal engine
problems.
7.
Listen for air leaks at induction module intake, exhaust
pipe and head gasket.
a.
Air escaping through the induction module indicates
a leaking intake valve.
b.
Air escaping through the exhaust pipe indicates a
leaking exhaust valve.
NOTES
•
If air is escaping through valves, check pushrod length.
•
Complete the cylinder leakage test(s). Install the spark
plugs. Verify that the throttle plate is in the closed position
before starting the engine.
DIAGNOSING SMOKING ENGINE OR HIGH
OIL CONSUMPTION
Before removing the cylinder heads, check for compression
and cylinder leakage. See
or
3.5 TROUBLESHOOTING, Cylinder Leakage
.
Check Prior to Cylinder Head Removal
1.
Oil tank overfilled.
2.
Oil carryover.
3.
Breather hose restricted.
4.
Restricted oil filter.
Check After Cylinder Head Removal
1.
Oil return passages for clogging.
2.
Valve guide seals.
3.
Valve guide to valve stem clearance.
4.
Gasket surface of both head and cylinder.
5.
Cylinder head casting's porosity allowing oil to drain into
combustion chamber.
6.
O-ring damaged or missing from oil pump/crankcase
junction.
ADJUSTMENT AND TESTING
General
Often only cylinder head and cylinder repair is needed (valves,
rings, piston, etc.). Service these components with the engine
in the frame. See
3.13 TOP END OVERHAUL: DISASSEMBLY,
Stripping Motorcycle for Top End Repair
.
After disassembling the top end only, it may be found that
crankcase repair is necessary. Crankcase repair requires
removal
of
engine
crankcase
from
chassis.
See
3.10 REMOVING ENGINE FROM CHASSIS
.
NOTE
Do not lay engine on primary side. Laying engine on primary
side will damage the clutch cable end fitting. If fitting is dam-
aged, replace the clutch cable.
Symptoms indicating a need for engine repair are often mis-
leading. If more than one symptom is present, possible causes
can be narrowed down to make a partial diagnosis. An above-
normal consumption of oil, for example, could be caused by
several mechanical faults. However, when accompanied by
blue-gray exhaust smoke and low engine compression, it
indicates worn piston rings. Low compression by itself however,
may indicate leaking valves, in addition to worn piston rings.
See
.
Piston slap is a condition where piston and/or cylinder are worn
out-of-round and are loose fitting, allowing the piston to slap
from front to rear of the cylinder as it moves up and down.
Frequently, valves, rings, pins, bushings and bearings need
attention at the same time. If any one of the above components
is worn, inspect all of these components. Repair or replace as
necessary.
2013 Sportster Service: Engine 3-15
3.6
ENGINE LUBRICATION SYSTEM
OIL PUMP OPERATION
The oil pump consists of two gerotor gear sets housed in one
pump body. One is feed and the other scavenge (return). Each
gerotor gear set has an inner and an outer gerotor. The inner
gerotor has one less lobe than the outer gerotor. Both gerotors
have fixed centers which are offset to each other. The inlet and
outlet sides of the pump are sealed by the tips and lobes of
the gerotor set. This prevents oil on the outlet side (high pres-
sure) from being transferred to the inlet side.
The feed pump distributes oil to the engine and has fewer lobes
than the scavenge pump, allowing for greater pressure devel-
opment. The scavenge pump returns oil to the tank and has
more lobes than the feed pump allowing for greater oil flow.
XL Models:
See
. Both rotor sets (3, 4) are driven
off a common shaft (2) that is coupled by gears to the crank-
shaft.
XR 1200X:
See
. The feed rotor set (4) is driven by
flats on the front intake camshaft (3). The scavenge rotor set
(5) is driven by flats on the rear exhaust camshaft (2).
2
1
5
3
4
sm06837
1. Body
2. Gear shaft
3. Scavenge rotor set
4. Feed rotor set
5. Cover
Figure 3-8. Oil Pump: XL Models
3-16 2013 Sportster Service: Engine
4.1
FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
NOTES
TORQUE VALUE
FASTENER
4.5 FUEL TANK: XR 1200X, Installing Fuel Tank
4.1-6.7 Nm
36-60
in-lbs
Air box to bracket fasteners: XR 1200X
4.3 AIR CLEANER ASSEMBLY, XL Models except
XL 1200V
9.5-13.6 Nm
84-120
in-lbs
Air cleaner breather screw
4.3 AIR CLEANER ASSEMBLY, XL 1200V
9.5-13.6 Nm
84-120
in-lbs
Air cleaner breather screw
4.3 AIR CLEANER ASSEMBLY, XL Models except
XL 1200V
4.1-6.8 Nm
36-60
in-lbs
Air cleaner cover screw
4.3 AIR CLEANER ASSEMBLY, XL 1200V
4.1-6.8 Nm
36-60
in-lbs
Air cleaner cover screw
4.3 AIR CLEANER ASSEMBLY, XL Models except
XL 1200V
4.5-6.8 Nm
40-60
in-lbs
Air filter screw
4.3 AIR CLEANER ASSEMBLY, XL 1200V
4.5-6.8 Nm
40-60
in-lbs
Air filter screw
4.13 EXHAUST SYSTEM: XL MODELS, Installation
13.6-20.4 Nm
120-180
in-lbs
Brake rod to bell crank screw
4.13 EXHAUST SYSTEM: XL MODELS, Installation
10.9-13.6 Nm
96-120
in-lbs
Cylinder head exhaust port nut
4.9 INDUCTION MODULE: XR 1200X, Installation
29.8-35.3 Nm
22-26 ft-lbs
Cylinder head oil feed flare fitting: XR
1200X
4.9 INDUCTION MODULE: XR 1200X, Installation
17.6-23.0 Nm
13-17 ft-lbs
Cylinder head oil feed line flare nut: XR
1200X
4.7 ENGINE TEMPERATURE (ET)
SENSOR, Installation
13.6-19.0 Nm
120-168
in-lbs
ET sensor
4.20 EVAPORATIVE EMISSIONS CONTROL, Char-
coal Canister
4.1-6.8 Nm
36-60
in-lbs
EVAP canister clip mounting screw
4.20 EVAPORATIVE EMISSIONS CONTROL, Char-
coal Canister
4.0-5.1 Nm
35-45
in-lbs
EVAP canister guard screw
4.20 EVAPORATIVE EMISSIONS CONTROL, Char-
coal Canister
23.1-29.9 Nm
17-22 ft-lbs
EVAP canister mounting bracket screw
4.20 EVAPORATIVE EMISSIONS CONTROL, Char-
coal Canister
23.1-29.9 Nm
17-22 ft-lbs
EVAP canister mounting bracket screw
4.14 EXHAUST SYSTEM: XR 1200X, Installation
40.7-44.7 Nm
30-33 ft-lbs
Exhaust clamp, lower nut: XR 1200X
4.14 EXHAUST SYSTEM: XR 1200X, Installa-
tion/SPECIAL SEQUENCE TO TIGHTEN
10.8-13.6 Nm
96-120
in-lbs
Exhaust flange nut: XR 1200X
4.13 EXHAUST SYSTEM: XL MODELS, Installation
2.3-4.5 Nm
20-40
in-lbs
Exhaust heat shield clamps
4.14 EXHAUST SYSTEM: XR 1200X, Installation
2.3-4.5 Nm
20-40
in-lbs
Exhaust heat shield clamps
4.13 EXHAUST SYSTEM: XL MODELS, Installation
40.7-44.8 Nm
30-33 ft-lbs
Exhaust pipe clamp bracket screw: XL
Models
4.13 EXHAUST SYSTEM: XL MODELS, Installation
27.1-40.7 Nm
20-30 ft-lbs
Exhaust pipe clamp nut: XL Models
4.5 FUEL TANK: XR 1200X, Assemble Fuel Tank
4.5-5.1 Nm
40-45
in-lbs
Filler housing screws
4.15 FUEL INJECTORS, Installation
6.8 Nm
60
in-lbs
Fuel hose retaining bracket screw
4.16 FUEL PUMP, Assembly
2.1-4.1 Nm
19-36
in-lbs
Fuel pump bracket mounting screw
4.16 FUEL PUMP, Installation
4.5-5.1 Nm
40-45
in-lbs
Fuel pump module mounting screw
4.17 FUEL FILTER ELEMENT, Installation
4.5-5.1 Nm
40-45
in-lbs
Fuel pump module mounting screw
4.5 FUEL TANK: XR 1200X, Installing Fuel Tank
2.7-3.4 Nm
24-30
in-lbs
Fuel tank cover screw: XR 1200X
4.5 FUEL TANK: XR 1200X, Installing Fuel Tank
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank fastener: XR 1200X
4.5 FUEL TANK: XR 1200X, Installing Fuel Tank
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank fastener: XR 1200X
2013 Sportster Service: Fuel System 4-1
NOTES
TORQUE VALUE
FASTENER
4.4 FUEL TANK: XL MODELS, Installing Fuel Tank
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank fasteners: XL Models
4.8 INDUCTION MODULE: XL MODELS, Installa-
tion
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank fasteners: XL Models
4.15 FUEL INJECTORS, Installation
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank fasteners: XL Models
4.10 IDLE AIR CONTROL (IAC), Installation: XL
Models
6.8 Nm
60
in-lbs
IAC mounting screw: XL models
4.8 INDUCTION MODULE: XL MODELS, Assembly
6.8 Nm
60
in-lbs
IAC mounting screw: XL Models
4.9 INDUCTION MODULE: XR 1200X, Assembly
6.8 Nm
60
in-lbs
IAC mounting screw: XR 1200X
4.10 IDLE AIR CONTROL (IAC), Installation: XR
1200X
6.8 Nm
60
in-lbs
IAC mounting screw: XR 1200X
4.8 INDUCTION MODULE: XL MODELS, Assembly
6.8 Nm
60
in-lbs
Induction module cable bracket screw:
XL Models
4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
1200X
27.1-32.5 Nm
20-24 ft-lbs
Induction module cover to cylinder head
fastener: XR 1200X
4.9 INDUCTION MODULE: XR 1200X, Installation
27.1-32.5 Nm
20-24 ft-lbs
Induction module cover to cylinder head
sockethead bolts: XR 1200X
4.9 INDUCTION MODULE: XR 1200X, Installation
10.2-13.6 Nm
90-120
in-lbs
Induction module cover to induction
module fastener: XR 1200X
4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
1200X
9.5-12.2 Nm
84-108
in-lbs
Induction module cover to induction
module fastener: XR 1200X
4.9 INDUCTION MODULE: XR 1200X, Installation
10.2-13.6 Nm
90-120
in-lbs
Induction module cover to wire form
fastener: XR 1200X
4.8 INDUCTION MODULE: XL MODELS, Installa-
tion
10.2-13.6 Nm
90-120
in-lbs
Induction module mounting bracket
screw: XL models
4.8 INDUCTION MODULE: XL MODELS, Assembly
4.0 Nm
35
in-lbs
Induction module screw: XL models
4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XL
Models
4.0 Nm
35
in-lbs
Induction module screw: XL Models
4.8 INDUCTION MODULE: XL MODELS, Installa-
tion
10.9-13.6 Nm
96-120
in-lbs
Intake manifold mounting screw: XL
models
4.9 INDUCTION MODULE: XR 1200X, Installation
10.3-13.6 Nm
90-120
in-lbs
Intake manifold mounting screw: XR
1200X
4.14 EXHAUST SYSTEM: XR 1200X, Installation
40.7-44.7 Nm
30-33 ft-lbs
Interconnect bracket to frame fastener:
XR 1200X
4.20 EVAPORATIVE EMISSIONS CONTROL, Char-
coal Canister
23.0-29.8 Nm
17-22 ft-lbs
Master cylinder mounting bracket, rear,
screw: XL models
4.13 EXHAUST SYSTEM: XL MODELS, Installation
40.7-44.7 Nm
30-33 ft-lbs
Muffler interconnect bracket mounting
screw: XL Models
4.14 EXHAUST SYSTEM: XR 1200X, Installation
61.0-67.8 Nm
45-50 ft-lbs
Muffler mount to frame, front fastener:
XR 1200X
4.14 EXHAUST SYSTEM: XR 1200X, Installation
20.3-27.1 Nm
15-20 ft-lbs
Muffler mount to frame, rear fastener:
XR 1200X
4.14 EXHAUST SYSTEM: XR 1200X, Installation
13.6-20.3 Nm
120-180
in-lbs
Muffler to front muffler mount fastener:
XR 1200X
4.13 EXHAUST SYSTEM: XL MODELS, Installation
20.4-25.8 Nm
15-19 ft-lbs
Muffler to interconnect bracket screw:
XL Models
4.14 EXHAUST SYSTEM: XR 1200X, Installation
13.6-20.3 Nm
120-180
in-lbs
Muffler to muffler bolt: XR 1200X
4.13 EXHAUST SYSTEM: XL MODELS, Installation
51.6-58.4 Nm
38-43 ft-lbs
Muffler torca clamp nut
4-2 2013 Sportster Service: Fuel System
NOTES
TORQUE VALUE
FASTENER
4.14 EXHAUST SYSTEM: XR 1200X, Installation
13.6-20.3 Nm
120-180
in-lbs
Muffler to rear muffler mount fastener:
XR 1200X
4.12 OXYGEN (O2) SENSOR, Installation
39.3-59.7 Nm
29-44 ft-lbs
O2 sensor
4.13 EXHAUST SYSTEM: XL MODELS, Installation
39.3-59.7 Nm
29-44 ft-lbs
O2 sensor
4.13 EXHAUST SYSTEM: XL MODELS, Installation
9.0-13.6 Nm
80-120
in-lbs
Sprocket cover, forward and lower
screws
4.9 INDUCTION MODULE: XR 1200X, Assembly
6.8 Nm
60
in-lbs
Throttle cable bracket screw: XR 1200X
4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
1200X
9.0 Nm
80
in-lbs
TMAP sensor screw
4.6 THROTTLE POSITION SENSOR
(TPS), Installation: XL Models
4.0 Nm
35
in-lbs
TPS screw: XL Models
4.6 THROTTLE POSITION SENSOR
(TPS), Installation: XR 1200X
3.3 Nm
29
in-lbs
TPS screw: XR 1200X
4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
1200X
9.5-12.2 Nm
84-108
in-lbs
Wire form to induction module cover
fastener: XR 1200X
2013 Sportster Service: Fuel System 4-3
4.2
SPECIFICATIONS: FUEL SYSTEM
SPECIFICATIONS
Table 4-1. Capacities: XL 883 Models
XL 883N
XL 883L
XL 883R
ITEM
METRIC
U.S.
METRIC
U.S.
METRIC
U.S.
12.5 L
3.3 gal
17.0 L
4.5 gal
12.5 L
3.3 gal
Fuel tank (total)
2.6 L
2.8 qt
2.6 L
2.8 qt
2.6 L
2.8 qt
Oil tank with filter
0.95 L
1.0 qt
0.95 L
1.0 qt
0.95 L
1.0 qt
Transmission (approximate)
3.0 L
0.8 gal
3.8 L
1.0 gal
3.0 L
0.8 gal
Low fuel warning light
Table 4-2. Capacities: XL 1200 Models and XR 1200X
XR 1200X
XL 1200X/V
XL 1200C/C ANV/CP/CA/CB
ITEM
METRIC
U.S.
METRIC
U.S.
METRIC
U.S.
13.2 L
3.5 gal
7.9 L
2.1 gal
17.0 L
4.5 gal
Fuel tank (total)
2.6 L
2.8 qt
2.6 L
2.8 qt
2.6 L
2.8 qt
Oil tank with filter
0.95 L
1.0 qt
0.95 L
1.0 qt
0.95 L
1.0 qt
Transmission
(approximate)
3.0 L
0.8 gal
2.5 L
0.65 gal
3.8 L
1 gal
Low fuel warning light
4-4 2013 Sportster Service: Fuel System
4.3
AIR CLEANER ASSEMBLY
XL MODELS EXCEPT XL 1200V
TORQUE VALUE
FASTENER
9.5-13.6 Nm
84-120
in-lbs
Air cleaner breather screw
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
Removal
1.
See
. Remove two screws (1) and trim insert
(2) from air cleaner cover (3).
2.
Remove air cleaner cover from air cleaner backplate (10).
3.
Remove air cleaner seal (4) from air cleaner cover.
4.
Remove three screws (5). Remove air filter element (6)
and gasket (7). Discard gasket.
5.
Remove O-rings from the breather screws (9). Discard
the O-rings.
Install air filter before running engine. Failure to do so can
draw debris into the engine and could result in engine
damage. (00207a)
6.
Remove two breather screws (9) from air cleaner back-
plate.
7.
Remove air cleaner backplate and gasket (11).
Installation
1.
See
. Position
new
gasket (11) and air cleaner
backplate (10) at induction module air inlet.
2.
Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to existing screws or use
new
breather screws (9). Install air cleaner backplate to
engine heads. Tighten to 84-120
in-lbs
(9.5-13.6 Nm).
3.
To prevent damage, apply a thin coat of engine oil to O-
rings (8). Install O-rings to breather tubes.
4.
Position
new
gasket (7) on air cleaner backplate. Line up
gasket holes with backplate holes.
5.
Install air filter element (6) onto backplate. Secure with
three
new
screws (5) or apply LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue) to
existing screws. Tighten to 40-60
in-lbs
(4.5-6.8 Nm).
6.
Install air cleaner seal (4) on air cleaner cover (3). Fit the
air cleaner seal around the entire edge of cover.
7.
Install air cleaner cover onto backplate. Do not pinch or
distort seal.
8.
Install trim insert (2) and air cleaner cover with two screws
(1). Tighten to 36-60
in-lbs
(4.1-6.8 Nm).
1
2
3
4
5
7
8
9
10
11
6
sm06706a
1. Screw (2)
2. Trim insert
3. Cover
4. Seal
5. Screw (3)
6. Filter element (includes item 7)
7. Filter element gasket
8. O-ring (2)
9. Breather screw (2)
10. Backplate
11. Gasket
Figure 4-1. Air Cleaner Assembly: All XL except XL 1200V
XL 1200V
TORQUE VALUE
FASTENER
9.5-13.6 Nm
84-120
in-lbs
Air cleaner breather screw
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
Removal
1.
See
. Remove the cover screw (1).
2.
Remove the cover (2) and the seal (3).
3.
Remove the three screws (4), the air filter element (5) and
gasket (9).
4.
Remove the O-rings (10). Discard the O-rings.
5.
Remove the two breather screws (6).
6.
Remove the backplate (7) and gasket (8).
7.
Inspect and replace parts as necessary.
8.
Clean or replace the air filter element as necessary. See
1.7 AIR FILTER, Cleaning Filter Element
2013 Sportster Service: Fuel System 4-5
Installation
1.
See
. Install the gasket (8) and backplate (7).
2.
Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to existing screws or use
new
breather screws (6). Install the breather screws.
Tighten to 84-120
in-lbs
(9.5-13.6 Nm).
3.
Apply engine oil to
new
O-rings (10). Install the O-rings
on the breather tubes.
4.
Install the filter gasket (9).
5.
Install the air filter element (5) and screws (4). Tighten to
40-60
in-lbs
(4.5-6.8 Nm).
6.
Fit the cover (2) to the seal (3).
7.
Install the cover and screw (1). Tighten to 36-60
in-lbs
(4.1-6.8 Nm).
8
4
7
2
5
1
3
9
10
6
sm07431
1. Screw
2. Cover
3. Seal
4. Screw (3)
5. Filter element
6. Breather screw
7. Backplate
8. Backplate gasket
9. Filter gasket
10. O-ring
Figure 4-2. Air Cleaner Assembly: XL 1200V
XR 1200X
Removal
1.
Remove the fuel tank. See
2.
HDI Models:
Disconnect active intake solenoid connector
[178].
NOTE
Leave the rubber coupling attached to the induction module.
3.
Lift the air box off induction module.
4.
See
. Disconnect the crankcase breather hoses
from the front and rear rocker cover fittings.
5.
Remove the air box assembly.
6.
Remove the cover and air filter element as necessary.
See
7.
Replace damaged parts as necessary.
1
2
4
1
3
sm07432
1. Breather hose
2. Clamp
3. Breather hose assembly
4. Coupling
Figure 4-3. Air Box: XR 1200X
Installation
NOTE
See
. Check that the breather hose assembly (4)
inside the air box does not interfere with the active air solenoid
flapper.
1.
Install all hoses.
2.
Snap the anchor barb (1) of the front crankcase vent hose
in the hole (2) in the air box bottom.
3.
If removed, install the air filter element and cover. See
4.
Seat the rubber coupling on the induction module.
5.
Verify that the clamps are in place.
6.
See
. Hold the air box close. Connect crankcase
vent hoses to the fittings (2) on the front and rear rocker
covers.
NOTE
The edge of hole in air box must encircle the groove in the
coupling.
4-6 2013 Sportster Service: Fuel System
7.
Seat the coupling into the air box opening.
8.
HDI Models:
Connect the active intake solenoid connector
[178].
9.
Install the fuel tank. See
2
1
3
4
sm05088
1. Anchor barb
2. Anchor hole in air box
3. Vent hose clamp
4. Breather hose assembly
Figure 4-4. Front Crankcase Vent Hose
2
2
1
sm05090
1. Induction module throat
2. Fittings on rocker covers
Figure 4-5. Air Box Connections
2013 Sportster Service: Fuel System 4-7
4.4
FUEL TANK: XL MODELS
PURGING AND DISCONNECTING FUEL
SUPPLY HOSE
When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)
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)
1.
Purge the fuel supply line of high pressure gasoline.
a.
Remove left side cover. See
.
b.
See
. Remove fuel pump connector from
ECM caddy cover (2).
c.
Unplug fuel pump connector [141].
d.
Start engine and allow vehicle to run.
e.
When engine stalls, operate starter for 3 seconds to
remove any remaining fuel from fuel hose.
f.
Shut off ignition.
2.
See
. Push up on release sleeve (1) on fuel
pump quick-connect fitting and pull down on fuel supply
hose fitting (2) to disconnect fuel supply hose (3) from fuel
pump module (4). Immediately clean up any fuel spills.
1
2
sm06566
1. Fuel pump wiring
2. ECM caddy cover (fuel pump connector inside)
Figure 4-6. Fuel Pump Connector: XL Models
4
1
2
3
sm01546c
1. Release sleeve (quick-connect fitting)
2. Fuel supply hose fitting
3. Fuel supply hose
4. Fuel pump module
Figure 4-7. Fuel Tank Quick-Connect Fitting
REMOVING FUEL TANK
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
Remove seat.
NOTES
•
If the fuel tank is being removed only to gain access to
items otherwise hidden, it is not necessary to drain the
fuel from the tank. If the fuel tank is to be disassembled
or repaired, follow the step below to drain the fuel.
•
Drain fuel into an approved container.
3.
Drain fuel tank:
a.
Obtain a suitable fuel transfer pump with a long, flex-
ible nozzle.
b.
Position vehicle upright. Remove fuel tank filler cap.
c.
Insert fuel transfer pump nozzle into fuel tank filler
spout. Aim nozzle toward right side of fuel tank to
avoid contacting and damaging fuel pump assembly.
d.
Direct the pump output into an approved container.
e.
Pump fuel until fuel tank is empty.
f.
Immediately wipe up any spilled fuel.
4.
See
. Remove vent hose (1) from fuel tank vent
nipple. Remove cable clip (3) securing fuel pump wiring
harness (2) to mounting boss on H-bracket.
5.
Unplug fuel pump connector [141].
4-8 2013 Sportster Service: Fuel System
6.
Remove protective caps, locknuts, screws and washers
from front and rear of fuel tank.
7.
Place a clean, soft cloth over front of fuel tank to keep tank
from contacting top fork clamp and damaging paint. Lift
up rear of fuel tank. Remove fuel pump harness from clip
on wire harness caddy latch clip on frame backbone.
8.
Lift fuel tank off motorcycle.
9.
Remove fuel pump assembly. See
2
3
1
sm06594c
1. Vent hose
2. Fuel pump wiring harness
3. Cable clip
Figure 4-8. Fuel Tank Vent Hose
CLEANING AND INSPECTION
When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)
1.
Clean fuel tank interior with commercial cleaning solvent
or a soap and water solution. Shake fuel tank to agitate
cleaning agent.
2.
Thoroughly flush fuel tank after cleaning. Allow fuel tank
to air dry.
3.
Carefully inspect fuel hose and vent hose for damage,
cuts, cracks, holes, wear or general deterioration. Replace
as necessary.
4.
Inspect the fuel tank for leaks or other damage. If a dam-
aged fuel tank cannot be successfully repaired, replace
it.
INSTALLING FUEL TANK
TORQUE VALUE
FASTENER
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank fasteners: XL
Models
NOTE
Verify wiring harnesses are not pinched between fuel tank and
frame during tank installation.
1.
Install fuel pump into fuel tank using
new
gasket. See
2.
See
. Position fuel tank on motorcycle. Verify
that front fuel tank brackets are located outboard of ignition
coil bracket (8).
3.
Install front fastener.
a.
Place washer (4) on long screw (2).
b.
From right to left, push screw through front fuel tank
bracket, ignition coil bracket and frame.
c.
Place second washer over screw.
d.
Hand-start locknut (5).
8
6
5
4
1
6
5
4
2
3
4
7
x0671a4x
1. Fuel tank (typical)
2. Screw (long)
3. Screw (short)
4. Washer (4)
5. Locknut (2)
6. Protective cap (2)
7. Cosmetic cover (2)
8. Ignition coil bracket
Figure 4-9. Fuel Tank Mounting (typical)
4.
See
. Place a clean, soft cloth over front of fuel
tank to keep tank from contacting top fork clamp and
damaging paint.
5.
Lift up rear of fuel tank.
6.
Place fuel pump wiring harness (1) into clip on wire har-
ness caddy latch clip on frame backbone tube. Verify that
2013 Sportster Service: Fuel System 4-9
the harness forms a loop (5) between caddy latch clip and
fuel pump module (6). Do not pinch harness between fuel
tank and frame backbone tube.
7.
Route fuel pump wiring harness down along left side of
H-bracket. Secure with cable clip (3). Push clip into hole
in mounting boss (2) on H-bracket.
8.
Install fuel tank.
a.
Lower rear of fuel tank into position.
b.
See
. Place washer (4) on short screw (3).
c.
From right to left, push screw through rear fuel tank
bracket and frame.
d.
Place second washer over screw
e.
Hand-start locknut (5).
f.
Tighten both front and rear fuel tank mounting
fasteners to 15-20 ft-lbs (20.3-27.1 Nm).
g.
Install protective caps (6) on screw ends.
9.
See
. Install vent hose onto fuel tank vent nipple.
10. Connect the fuel pump connector [141] housings.
1
2
3
4
5
6
sm06571a
1. Fuel pump wiring harness
2. Cable clip mounting boss on ECM caddy
3. Cable clip
4. Wire harness caddy latch clip
5. Fuel pump wiring harness loop
6. Fuel pump module
Figure 4-10. Fuel Pump Wiring Harness Routing
CONNECTING FUEL HOSE AND FILLING
FUEL TANK
To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)
1.
See
. Connect fuel hose.
a.
Push up on release sleeve (1).
b.
Push fuel hose fitting (2) into fuel pump module fuel
pump quick-connect fitting.
c.
Pull down on release sleeve to lock quick-connect
fitting.
d.
Tug on fuel hose fitting to make sure it is securely
locked in place.
2.
See
. Install vent hose onto vent nipple on fuel
tank.
Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)
Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)
3.
Fill fuel tank and carefully inspect for leaks around fuel
pump module.
4.
Install main fuse.
5.
Turn ignition switch ON and verify fuel pump is activated.
Carefully inspect for leaks at quick-connect fitting. Turn
ignition switch OFF.
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)
6.
Install seat.
VAPOR VALVE
Excessive pressure can build in the fuel tank if vapor valve
is not mounted vertically with long fitting to top. Leaks
due to excessive pressure can cause a fire or explosion,
which could result in death or serious injury. (00265a)
See
. The fuel tank is vented through a standpipe
(vent tube) within the tank. A hose (1) at the base of the fuel
tank is connected to the standpipe.
Keep vent and vapor valve lines away from exhaust and
engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00263a)
4-10 2013 Sportster Service: Fuel System
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